Fuse life management in an electric mobile application

ABSTRACT

A system includes a vehicle including a motive electrical power path; a power distribution unit having a current protection circuit disposed in the motive electrical power path, the current protection circuit comprising a fuse; a controller, comprising: a fuse status circuit structured to determine a fuse event value; a fuse management circuit structured to provide a fuse event response based on the fuse event value; and a fuse life description circuit structured to determine a fuse life remaining value, wherein the fuse event value comprises a representation that the fuse life remaining value is below a threshold value, and wherein the fuse management circuit is further structured to provide the fuse event response further based on the fuse life remaining value.

CLAIM OF PRIORITY

This application is a continuation of U.S. patent application Ser. No.16/380,857, filed Apr. 10, 2019, and entitled “SYSTEM, METHOD, ANDAPPARATUS FOR POWER DISTRIBUTION IN AN ELECTRIC MOBILE APPLICATION USINGA COMBINED BREAKER AND RELAY” (EATN-2500-U01).

U.S. patent application Ser. No. 16/380,857 claims priority to thefollowing U.S. Provisional Patent Applications: Ser. No. 62/675,622,filed May 23, 2018, and entitled “SYSTEM, METHOD, AND APPARATUS USING ACOMBINED BREAKER AND RELAY IN A MOBILE APPLICATION” (EATN-2012-P01);Ser. No. 62/655,956, filed Apr. 11, 2018, and entitled “SYSTEM, METHOD,AND APPARATUS USING A COMBINED BREAKER AND RELAY IN A MOBILEAPPLICATION” (EATN-2011-P01); and Ser. No. 62/655,631, filed Apr. 10,2018, and entitled “SYSTEM, METHOD, AND APPARATUS USING A COMBINEDBREAKER AND RELAY IN A MOBILE APPLICATION” (EATN-2009-P01).

U.S. patent application Ser. No. 16/380,857 is a continuation-in-part ofand claims priority to U.S. patent application Ser. No. 16/184,185,filed Nov. 8, 2018, and entitled “POWER DISTRIBUTION UNIT AND FUSEMANAGEMENT FOR AN ELECTRIC MOBILE APPLICATION” (EATN-2300-U01).

U.S. patent application Ser. No. 16/184,185 claims priority to thefollowing U.S. Provisional Patent Applications: Ser. No. 62/583,355,filed Nov. 8, 2017, and entitled “ACTIVE/PASSIVE THERMAL PROTECTION OFTEMPERATURE SENSITIVE COMPONENTS” (EATN-2001-P01); Ser. No. 62/583,367,filed Nov. 8, 2017, and entitled “FUSE AND CONTACTOR FOR CIRCUITPROTECTION” (EATN-2002-P01); and Ser. No. 62/583,428, filed Nov. 8,2017, and entitled “FUSE LIFE EXTENDER METHOD” (EATN-2006-P01).

U.S. patent application Ser. No. 16/184,185 also claims priority to thefollowing Indian Provisional Patent Applications: Serial Number201711039846, filed Nov. 8, 2017, and entitled “FUSE CURRENT MEASUREMENTWITH ACTIVE INJECTION SYSTEM” (EATN-2003-P01-IN); and Serial Number201711039850, filed Nov. 8, 2017, and entitled “UNIQUE CURRENT INJECTIONWAVEFORM TO IMPROVE INJECTION MEASUREMENT ACCURACY” (EATN-2008-P01-IN).

U.S. patent application Ser. No. 16/380,857 is a continuation-in-part ofand claims priority to International Application Serial No.PCT/EP1880611, filed Nov. 8, 2018, and entitled “POWER DISTRIBUTION UNITAND FUSE MANAGEMENT FOR AN ELECTRIC MOBILE APPLICATION” (EATN-2300-WO).

PCT/EP1880611 claims priority to the following U.S. Provisional PatentApplications: Ser. No. 62/583,355, filed Nov. 8, 2017, and entitled“ACTIVE/PASSIVE THERMAL PROTECTION OF TEMPERATURE SENSITIVE COMPONENTS”(EATN-2001-P01); Ser. No. 62/583,367, filed Nov. 8, 2017, and entitled“FUSE AND CONTACTOR FOR CIRCUIT PROTECTION” (EATN-2002-P01); and Ser.No. 62/583,428, filed Nov. 8, 2017, and entitled “FUSE LIFE EXTENDERMETHOD” (EATN-2006-P01).

PCT/EP1880611 also claims priority to the following Indian ProvisionalPatent Applications: Serial Number 201711039846, filed Nov. 8, 2017, andentitled “FUSE CURRENT MEASUREMENT WITH ACTIVE INJECTION SYSTEM”(EATN-2003-P01-IN); and Serial Number 201711039850, filed Nov. 8, 2017,and entitled “UNIQUE CURRENT INJECTION WAVEFORM TO IMPROVE INJECTIONMEASUREMENT ACCURACY” (EATN-2008-P01-IN).

All of the above patent documents are incorporated herein by referencein their entirety.

FIELD

Without limitation to a particular field of technology, the presentdisclosure is directed to electrical power distribution and circuitprotection, and more particularly to electronic power distribution andcircuit protection for highly variable load applications.

BACKGROUND

Electrical power distribution in many applications is subject to anumber of challenges. Applications having a highly variable load, suchas mobile applications or vehicles, subject fuses in the power channelsto rapid swings in power throughput and induce thermal and mechanicalstresses on the fuses. Certain applications have a high cost fordown-time of the application. Certain applications, including mobileapplications, are subject to additional drawbacks from loss of power,such as loss of mobility of the application unexpectedly, including atan inconvenient location, while in traffic, or the like. Electricalsystems in many applications are complex, with multiple components inthe system, and variations in the wiring and environment of theelectrical system, leading to variations in the electrical systemresponse, introduction of noise, variations in system resonantfrequencies, and/or variations in system capacitance and/or inductance,even for nominally identical installations. These complexities introduceadditional challenges for high resolution and/or highly precisedeterminations of the electrical characteristics of aspects of thesystem. Additionally, highly variable and/or mobile systems provideadditional challenges for diagnostics and determinations about aspectsof the electrical system, as highly invasive active determinations maynot be acceptable to application performance, and/or the system may notprovide many opportunities, or only brief opportunities, for makingdeterminations about the electrical system.

Electric mobile applications, such as electric vehicles andhigh-capability hybrid vehicles provide numerous challenges forpreviously known inverter and power electronics systems. Mobileapplications include on-highway vehicles, off-highway vehicles,commercial and passenger car vehicles, and/or off road applicationsincluding any type of vehicle or mobile equipment.

For example, many mobile applications, such as commercial and passengervehicles, are highly cost sensitive to both initial costs of a system,and to ongoing operating costs. Additionally, downtime for service,maintenance, or system failures has a very high cost, due to largevolumes and competitive markets. Accordingly, even modest improvementsto initial costs, operating costs, and reliability can make asignificant impact on the outcome of the system, or make anon-marketable system competitive.

Mobile applications have limited space and weight available forcomponents of the drive system. For example, vehicle sizing and fuelefficiency concerns drive many applications to reduce both the size andthe weight of the vehicle, and to accommodate vehicle shape foraerodynamics, according to the specific application, and/or according touser or customer preferences. Additionally, mobile applications have alarge number of features, and application requirements and customerpreferences are such that additional features are almost always valueadded if the system can accommodate them while meeting otherconstraints. Accordingly, reducing the size and weight of a givencomponent provides value to the application, whether through a netreduction of the application size and weight, or through the ability toaccommodate additional features within the same size and weight.

Mobile applications generally have a large number of components, andoften many of the components are provided by third parties andintegrated by a primary manufacturer or original equipment manufacturer(OEM). Accordingly, reductions in the size or weight of a componentprovide for easier integration of components, and/or are required toaccommodate a limited space claim during the design phase, upgrades,retro-fits, or the like. Additionally, both the large number ofcomponents and the integration of many components from separatecomponent providers introduce complexities into the integration of themobile application. Further, each component and sub-component, and eachinterface between components, creates a failure point that can cause aservice event, undesirable operation, application downtime, and/or amission disabling failure. Failures occurring in mobile applicationsoften occur at a location that is inconvenient for service access, andmay require moving the degraded or disabled vehicle to a servicelocation before the failure can be corrected. Accordingly, componentsthat have a reduced number of sub-components, that can utilizestandardized interfaces, and/or that have a reduced number of interfacesare desirable for mobile applications. Some mobile applications areproduced in very high volume, and even modest reductions in either thenumber of interfaces or the number of sub-components can add high valueto the system.

Some mobile applications are produced in small volumes with shortengineering design time, and accordingly a reduction in the number ofinterfaces can greatly reduce the design cycle time, providing asignificant benefit where engineering costs cannot be distributed acrossa high volume of products. Some mobile applications are produced asretro-fit or upgrades, and/or include a number of options where acomponent may appear on certain models or versions of the mobileapplication, but may not be on other models or versions, and/or may beinstalled in a different location on the vehicle than on other models orversions. For example, mobile applications may have components addedpost-manufacturing as part of a customer option, to accommodate newregulations, to support an environmental policy (e.g., of a company, orfor a fleet of vehicles), to upgrade a vehicle, and/or to repurpose orremanufacture a vehicle. Accordingly, components having a reduced size,a reduced weight, and/or a reduced number of interfaces provide foreasier post-manufacturing changes, a greater number of options in thepost-manufacturing changes, and/or greater reliability for componentsthat are installed using non-standardized or low volume processes thatmay not be as refined as a standardized process for a high volumeapplication. Additionally, size and weight savings in components of theapplication can provide for the inclusion of additional features withinthe same cost and weight profile.

Mobile applications often have a large differential in duty cycle evenfor systems that have similar power ratings. Further, mobileapplications often involve systems that are sold or otherwisetransferred, where the same system can experience a significant changein the duty cycle and operating conditions after the system is in thehands of a user. Accordingly, a lack of flexibility in design parametersat the time of initial sale can limit the available markets for asystem, and a lack of flexibility in design parameters in use can resultin increased failures later in the life cycle of the system.

Electrical power distribution in many applications is subject to anumber of challenges. Presently available systems for providingconversion between electric power and other power sources and loadssuffer from a number of drawbacks. Variability in the load types,performance characteristics, and overall system arrangements lead todifficult integration issues that reduce the desirability of hybridpower utilization for many applications, and reduce the available systemefficiencies as many aspects of an application are not integrated intothe hybrid power arrangement. Additionally, many applications, such asoff-road applications, and certain specific on-road applications thathave unusual equipment or duty cycles, are low volume and are noteconomically justifiable to design and integrate a hybrid power system.Systems having a number of varying load and power devices and subsystemsadditionally create integration challenges, leading to a multiplicity ofpower conversion devices distributed around the system and customizedfor the particular system. Accordingly, it may not be economicallyjustifiable to create a hybrid power system for such systems usingpresently known technologies.

SUMMARY

In an aspect, a mobile application may include a motive power circuit,the motive power circuit including a power storage device and anelectrical load, wherein the power storage device and the electricalload may be selectively electrically coupled through a power bus; apower distribution unit (PDU) electrically interposed between the powerstorage device and the electrical load, wherein the PDU may include abreaker/relay positioned on one of a high side and a low side of thepower storage device; wherein the breaker/relay includes a fixed contactelectrically coupled to the power bus; a moveable contact selectivelyelectrically coupled to the fixed contact, and wherein the moveablecontact allows power flow through the power bus when electricallycoupled to the fixed contact, and prevents power flow through the powerbus when not electrically coupled to the fixed contact; and an armatureoperationally coupled to the moveable contact, such that the armature ina first position prevents electrical coupling between the moveablecontact and the fixed contact, and the armature in a second positionallows electrical coupling between the moveable contact and the fixedcontact; and a first biasing member biasing the armature into one of thefirst position or the second position. In embodiments, the mobileapplication may include a standard on/off circuit having at least twostates, wherein the standard on/off circuit in a first state provides anactuating signal and in a second state prevents the actuating signal; acurrent response circuit structured to determine a current in the powerbus, and further structured to block the actuating signal of thestandard on/off circuit in response to the current in the power busindicating a high current value; and wherein the armature may beresponsive to the actuating signal to electrically couple the moveablecontact to the fixed contact. The breaker/relay may include an auxiliaryoff circuit structured to interpret an auxiliary command, and furtherstructured to block the actuating signal of the standard on/off circuitin response to the auxiliary command indicating that the moveablecontact should not be electrically coupled to the fixed contact. Theauxiliary command may include at least one command selected from thecommands consisting of: an emergency shutdown command, a service eventindicator, a maintenance event indicator, an accident indicator, avehicle controller request, and a device protection request. Thestandard on/off circuit may include one of a keyswitch voltage and akeyswitch indicator. The breaker/relay may include a contact forcespring operationally interposed between the armature and the moveablecontact, such that in response to the armature being in the secondposition, the contact force spring may be at least partially compressed,and wherein the contact force spring may be configured such that aLorentz force acting between the fixed contact and the moveable contactfurther compresses the contact force spring in response to a selectedcurrent value. The high current value may be lower than the selectedcurrent value. The moveable contact may include a body extending awayfrom the fixed contact, wherein the body of the moveable contact may bedisposed within a plurality of splitter plates, and wherein theplurality of splitter plates may be at least partially disposed within apermanent magnet. The mobile application may include a charging circuit,and wherein the breaker/relay may be further positioned on the chargingcircuit. The charging circuit may include a quick charging circuithaving a higher current throughput value than a rated current foroperations of the electrical load. The mobile application may include astandard on/off circuit having at least two states, wherein the standardon/off circuit in a first state provides an actuating signal and in asecond state prevents the actuating signal; a current response circuitstructured to determine a current in the power bus, and furtherstructured to block the actuating signal of the standard on/off circuitin response to the current in the power bus indicating a high currentvalue; wherein the current response circuit may be further structured toutilize a first threshold current value for the high current value inresponse to the motive power circuit powering the electrical load, andthe utilized a second threshold current value for the high current valuein response to the charging circuit coupled to a quick charging device;and wherein the armature may be responsive to the actuating signal toelectrically couple the moveable contact to the fixed contact. Theelectrical load may include at least one load selected from the loadsconsisting of a motive power load, a regeneration load, a power take-offload, an auxiliary device load, and an accessory device load. The mobileapplication may include a second breaker/relay disposed on the other ofthe high side or the low side of the power storage device. The powerstorage device may include a rechargeable device. The power storagedevice may include at least one device selected from the devicesconsisting of a battery, a capacitor, and a fuel cell.

In an aspect, a breaker-relay may include a fixed contact electricallycoupled to a power bus for a mobile application; a moveable contactselectively electrically coupled to the fixed contact; an armatureoperationally coupled to the moveable contact, such that the armature ina first position prevents electrical coupling between the moveablecontact and the fixed contact, and the armature in a second positionallows electrical coupling between the moveable contact and the fixedcontact; a first biasing member biasing the armature into one of thefirst position or the second position; a standard on/off circuit havingat least two states, wherein the standard on/off circuit in a firststate provides an actuating signal and in a second state prevents theactuating signal; a current response circuit structured to determine acurrent in the power bus, and further structured to block the actuatingsignal of the standard on/off circuit in response to the current in thepower bus indicating a high current value; and wherein the armature maybe responsive to the actuating signal to electrically couple themoveable contact to the fixed contact. In embodiments, the mobileapplication may include at least two electrical current operatingregions. The current response circuit may be further structured toadjust the high current value in response to an active one of the atleast two electrical current operating regions.

In an aspect, a method may include detecting a current value, thecurrent value including an electrical current flow through a power buselectrically coupled to a breaker/relay; determining whether the currentvalue exceeds a threshold current value; and in response to the currentvalue exceeding the threshold current value, actuating an armature toopen contacts in the breaker/relay, thereby preventing the electricalcurrent flow through the power bus. In embodiments, the method mayinclude applying a contact force to a moveable one of the contacts ofthe breaker/relay; and opening the contacts in response to a repulsiveforce generated between the contacts in response to the electricalcurrent flow through the power bus. The method may further includeselecting the contact force such that the opening the contacts occurs ata selected current flow value of the electrical current flow. The methodmay further include actuating the armature to open the contacts in thebreaker/relay such that the moveable one of the contacts does not returnto a closed position after the opening the contacts in response to therepulsive force. The actuating the armature may be commenced before theopening the contacts in response to the repulsive force.

In an aspect, a breaker/relay may include a fixed contact electricallycoupled to a power bus; a moveable contact selectively electricallycoupled to the fixed contact; an armature operationally coupled to themoveable contact, such that the armature in a first position preventselectrical coupling between the moveable contact and the fixed contact,and the armature in a second position allows electrical coupling betweenthe moveable contact and the fixed contact; a first biasing memberbiasing the armature into one of the first position or the secondposition; a current response circuit structured to determine a currentin the power bus, and further structured to command the armature to thefirst position in response to the current in the power bus indicating ahigh current value. In embodiments, the breaker/relay may furtherinclude a contact force spring operationally interposed between thearmature and the moveable contact, such that in response to the armaturebeing in the second position, the contact force spring may be at leastpartially compressed, and wherein the contact force spring may beconfigured such that a Lorentz force acting between the fixed contactand the moveable contact further compresses the contact force spring inresponse to a selected current value. The high current value may belower than the selected current value. The moveable contact may includea body extending away from the fixed contact, wherein the body of themoveable contact may be disposed within a plurality of splitter plates,and wherein the plurality of splitter plates may be at least partiallydisposed within a permanent magnet. The power bus may be a power bus fora mobile application. The mobile application may include at least twoelectrical current operating regions.

In an aspect, a mobile application may include a motive power circuit,the motive power circuit including a power storage device and anelectrical load, wherein the power storage device and the electricalload may be selectively electrically coupled through a power bus; apower distribution unit (PDU) electrically interposed between the powerstorage device and the electrical load, wherein the PDU may include abreaker/relay positioned on one of a high side and a low side of thepower storage device; wherein the breaker/relay may include: a pluralityof fixed contacts electrically coupled to the power bus; a plurality ofmoveable contacts corresponding to the plurality of fixed contacts,wherein the plurality of moveable contacts may be selectivelyelectrically coupled to the plurality of fixed contacts, and wherein themoveable contacts allow power flow through the power bus whenelectrically coupled to the fixed contacts, and prevent power flowthrough the power bus when not electrically coupled to the fixedcontacts; an armature operationally coupled to at least one of themoveable contacts, such that the armature in a first position preventselectrical coupling between the at least one of the moveable contactsand the corresponding one of the fixed contacts, and the armature in asecond position allows electrical coupling between the at least one ofthe moveable contacts and the corresponding one of the fixed contacts; afirst biasing member biasing the armature into one of the first positionor the second position; and an arc suppression assembly structured toguide and disperse an opening arc between each of the plurality ofmoveable contacts and the corresponding fixed contacts. In embodiments,the plurality of moveable contacts may be linked as a dual pole singlethrow contacting arrangement. The armature may be operationally coupledto both of the moveable contacts. The plurality of moveable contacts maybe separately controllable. The mobile application may further include apre-charge circuit coupled in parallel with at least one of the fixedcontacts. The pre-charge circuit may include a solid state pre-chargecircuit. The moveable contacts and the fixed contacts may be disposedwithin a single housing. The mobile application may further include amagnetic actuator coupled to one of the moveable contacts, and whereinall of the plurality of moveable contacts may be responsive to themagnetic actuator. The arc suppression assembly may include a pluralityof splitter plates and at least one permanent magnet. At least one ofthe plurality of splitter plates may be positioned within arc dispersionproximity of more than one of the moveable contacts. The permanentmagnet may be positioned within arc guidance proximity of more than oneof the moveable contacts. The mobile application may further include acurrent sensor structured to determine an electrical current value inresponse to electrical current flowing through at least one of themoveable contacts, the mobile application may further include acontroller structured to interpret the electrical current value and tocommand the at least one of the moveable contacts to the first positionin response to the electrical current value exceeding a threshold value.The at least one of the moveable contacts may be responsive to a Lorentzforce to physically move to the first position in response to theelectrical current value exceeding a second threshold value. The secondthreshold value may be greater than the threshold value. The controllermay be further structured to adjust the threshold value in response toan expected electrical current value. The controller may be furtherstructured to increase the threshold value in response to determiningthat a charge operation of a battery may be active. The mobileapplication may further include a bus bar electrically coupling two ofthe plurality of moveable contacts. The bus bar may include a hardwareconfiguration in the region of each of the moveable contacts, whereinthe hardware configuration provides for a physical response force of themoveable contacts in response to a current value through the power bus.The hardware configuration may include at least one configurationselected from the configurations consisting of: an area of the bus barin proximity to a current providing portion of the power bus; and apositioning of a portion of the bus bar in proximity to the currentproviding portion of the power bus. The mobile application may furtherinclude a plurality of current sensors, each of the plurality of currentsensors operationally coupled to one of the plurality of moveablecontacts. A first one of the plurality of moveable contacts may couple afirst circuit of the power bus, and wherein a second one of theplurality of moveable contacts couples a second circuit of the powerbus, and wherein the first circuit and the second circuit may be powercircuits for separate electrical loads. The PDU further may include acoolant coupling configured to interface with a coolant source of themobile application, and an active cooling path configured to thermallycouple the coolant source with the fixed contacts.

In an aspect, a breaker/relay may include a plurality of fixed contactselectrically coupled electric load circuits for a mobile application; aplurality of moveable contacts, each moveable contact selectivelyelectrically coupled to a corresponding one of the plurality of fixedcontacts; a plurality of armatures each operationally coupled to acorresponding one of the moveable contacts, such that each armature in afirst position prevents electrical coupling between the correspondingmoveable contact and the corresponding fixed contact, and each armaturein a second position allows electrical coupling between thecorresponding moveable contact and the corresponding fixed contact; anda current response circuit structured to determine a current in each ofthe electric load circuits, and further structured to provide anarmature command to open the corresponding one of the moveable contactsin response to the current in the corresponding electrical load circuitindicating a high current value. In embodiments, the breaker/relay mayfurther include a plurality of biasing members each operationallycoupled to a corresponding one of the plurality of moveable contacts,and configured to bias the corresponding one of the plurality ofarmatures into one of the first position or the second position. A firsthigh current value for a first one of the electric load circuits mayinclude a distinct value from a second high current value for a secondone of the electric load circuits. The breaker/relay may further includea first biasing member operationally coupled to a corresponding one ofthe moveable contacts for the first electric load circuit, a secondbiasing member operationally coupled to a corresponding one of themoveable contacts for the second electric load circuit, and wherein thefirst biasing member may include a distinct biasing force from thesecond biasing member. A first moveable contact for the first electricload may include a distinct mass value from a second moveable contactfor the second electric load.

In an aspect, a method may include determining a first current value ina first electric load circuit for a mobile application; determining asecond current value in a second electric load circuit for the mobileapplication; and in response to one of the first current value exceedinga first high current value or the second current value exceeding asecond high current value, providing armature command to open acontactor for a corresponding one of the first electric load circuit orthe second electric load circuit. In embodiments, the method may furtherinclude diffusing an arc for the opened contactor to a plurality ofsplitter plates positioned in proximity to the opened contactor. Themethod may further include determining a first physical current openingvalue for the first electric load circuit and a second physical currentopening value for the second electric load circuit, providing the firsthigh current value as a value lower than the first physical currentopening value, and providing the second high current value as a valuelower than the second physical current opening value.

In an aspect, a system may include a housing; a breaker/relay devicepositioned in the housing, wherein the breaker/relay device may beconfigured to interrupt a motive power circuit for an electrical vehiclesystem, where the housing may be disposed on the electrical vehiclesystem; wherein the breaker/relay device may include a physical openingresponse portion responsive to a first current value in the motive powercircuit, and a controlled opening response portion responsive to asecond current value in the motive power circuit; and a prechargecircuit electrically coupled in parallel to the breaker/relay device. Inembodiments, the precharge circuit may be positioned within the housing.The first current value may be greater than the second current value.The physical opening response portion may include a first biasing memberbiasing an armature of the breaker/relay device into an open positionfor a contactor of the motive power circuit, and a selected differencebetween a first force of the armature closing the contactor and a secondforce of the first biasing member opening the contactor. The controlledopening response portion may include a current sensor providing acurrent value through the motive power circuit, and a current responsecircuit structured to command an armature to open a contactor inresponse to the current value exceeding the second current value. Thebreaker/relay device may include a dual-pole breaker/relay device. Thebreaker/relay device may include a single-pole breaker/relay device. Thebreaker/relay device may be positioned on one of a high side circuit ora low side circuit of the motive power circuit. The system may furtherinclude a pyro-switch device positioned on the other of the high sidecircuit or the low side circuit. The system may further include aphysical opening response adjustment circuit structured to determine afirst current value adjustment, and to adjust the physical openingresponse portion in response to the first current value adjustment. Thephysical opening response adjustment circuit may be further structuredto adjust the physical opening response portion by performing at leastone operation selected from the operations consisting of: adjusting acompression of the first biasing member; adjusting the first force; andadjusting the second force. The physical opening response adjustmentcircuit may be further structured to adjust the physical openingresponse portion in response to an operating condition of the electricalvehicle system. The controlled opening response portion may be furtherstructured to command the armature to open the contactor in response toat least one value selected from the values consisting of: atime-current profile of the motive power circuit; a time-currenttrajectory of the motive power circuit; a time-current area value of themotive power circuit; a rate of change of a current value through themotive power circuit; and a difference between a current value throughthe motive power circuit and the second current value.

In an aspect, a method may include determining a current value through amotive power circuit of an electrical vehicle system; opening the motivepower circuit with a physical response of a breaker/relay device inresponse to the current value exceeding a first current value; andopening the motive power circuit with a controlled response of anarmature operationally coupled to a contactor of the breaker/relaydevice in response to the current value exceeding a second currentvalue. In embodiments, the first current value may be greater than thesecond current value. The method may further include determining a firstcurrent value adjustment in response to an operating condition of theelectrical vehicle system, and adjusting the first current value inresponse to the first current value adjustment. The method may furtherinclude adjusting the physical opening response portion by performing atleast one operation selected from the operations consisting of:adjusting a compression of a first biasing member operationally coupledto the contactor of the breaker/relay device; adjusting a first force ofthe first biasing member operationally coupled to the contactor of thebreaker/relay device; and adjusting a second force of the armatureoperationally coupled to the contactor of the breaker/relay device. Themethod may further providing controlling the response of the armature toopen the contactor in response to at least one value selected from thevalues consisting of: a time-current profile of the motive powercircuit; a time-current trajectory of the motive power circuit; atime-current area value of the motive power circuit; a rate of change ofthe current value through the motive power circuit; and a differencebetween the current value through the motive power circuit and thesecond current value.

In an aspect, a breaker/relay may include a fixed contact electricallycoupled to a motive power circuit for a mobile application; a moveablecontact selectively electrically coupled to the fixed contact, whereinthe moveable contact in a first position allows power to flow throughthe motive power circuit, and the moveable contact in a second positiondoes not allow power to flow through the motive power circuit; and aphysical opening response portion responsive to a current value in themotive power circuit, wherein the physical opening response portion maybe configured to move the moveable contact to the second position inresponse to the current value exceeding a threshold current value. Inembodiments, the fixed contact may include a first fixed contact, thebreaker/relay may further include a second fixed contact, wherein themoveable contact may include a first moveable contact corresponding tothe first fixed contact, the breaker/relay may further include a secondmoveable contact corresponding to the second fixed contact, and a busbar electrically coupling the first moveable contact to the secondmoveable contact. The bus bar may include a hardware configuration inthe region of each of the moveable contacts, wherein the hardwareconfiguration provides for a physical response force of the moveablecontacts in response to a current value through the motive powercircuit. The hardware configuration may include at least oneconfiguration selected from the configurations consisting of: an area ofthe bus bar in proximity to a current providing portion of the motivepower circuit; and a positioning of a portion of the bus bar inproximity to the current providing portion of the motive power circuit.The physical opening response portion may include a contact area betweenthe fixed contact and the moveable contact, and a biasing memberproviding a contact force to the moveable contact, wherein the contactarea and the contact force may be configured to move the moveablecontact to the second position in response to the current valueexceeding the threshold current value. The physical opening responseportion further may include a mass value of the moveable contacts,wherein the contact area, the contact force, and the mass value may beconfigured to move the moveable contact away from the first position ata selected velocity value in response to the current value exceeding thethreshold current value. The breaker/relay may further include anarmature operatively coupled to the moveable contact and capable to movethe moveable contact between the first position and the second position;a current response circuit structured to determine a current in mobilepower circuit, and further structured to provide an armature command tocommand the moveable contact to the first position in response to thecurrent in the mobile power circuit exceeding a second current thresholdvalue. The second current threshold value may be lower than thethreshold current value. The selected velocity value may be configuredto be high enough such that the moveable contact does not return to thefirst position after moving away from the first position. The moveablecontact may be pivotally coupled to a pivoting arm.

In an aspect, a method may include operating a moveable contact betweena first position in contact with a fixed contact and allowing power toflow through a motive power circuit for a mobile application, and asecond position not in contact with the fixed contact and preventingpower flow through the motive power circuit for the mobile application;and configuring a physical opening response portion of a breaker/relayincluding the moveable contact and the fixed contact, such that thephysical opening response portion moves the moveable contact to thesecond position in response to a current value exceeding a thresholdcurrent value. Configuring the physical opening response portion mayinclude selecting a biasing force of a biasing member providing contactforce to the moveable contact. Configuring the physical opening responseportion may include selecting a contact area between the moveablecontact and the fixed contact. Configuring the physical opening responseportion may include selecting a mass of the moveable contact.Configuring the physical opening response portion may include selectinga bus bar configuration, wherein the bus bar couples two moveablecontacts, and wherein the bus bar configuration may include at least oneof a bus bar area in proximity to a current providing portion of themobile power circuit or a positioning of a portion of the bus bar inproximity to the current providing portion of the mobile power circuit.The method may further include determining a current in the mobile powercircuit, and providing an armature command to command the moveablecontact to the first position in response to the current in the mobilepower circuit exceeding a second current threshold value. The method mayfurther include configuring the physical opening response portion suchthat the moveable contact does not return to the first position aftermoving away from the first position.

In an aspect, a mobile application may include a motive power circuit,the motive power circuit including a power storage device and anelectrical load, wherein the power storage device and the electricalload may be selectively electrically coupled through a power bus; apower distribution unit (PDU) electrically interposed between the powerstorage device and the electrical load, wherein the PDU may include abreaker/relay positioned on one of a high side and a low side of thepower storage device; wherein the breaker/relay may include: a fixedcontact electrically coupled to the power bus; a moveable contactselectively electrically coupled to the fixed contact, and wherein themoveable contact allows power flow through the power bus whenelectrically coupled to the fixed contact, and prevents power flowthrough the power bus when not electrically coupled to the fixedcontact; an armature operationally coupled to the moveable contact, suchthat the armature in a first position prevents electrical couplingbetween the moveable contact and the fixed contact, and the armature ina second position allows electrical coupling between the moveablecontact and the fixed contact; a first biasing member biasing thearmature into one of the first position or the second position; abreaker/relay electronics component, including a standard on/off circuithaving at least two states, wherein the standard on/off circuit in afirst state provides an actuating signal and in a second state preventsthe actuating signal; a current response circuit structured to determinea current in the power bus, and further structured to block theactuating signal of the standard on/off circuit in response to thecurrent in the power bus indicating a high current value; and whereinthe armature may be responsive to the actuating signal to electricallycouple the moveable contact to the fixed contact. In embodiments, thebreaker/relay further may include an auxiliary off circuit structured tointerpret an auxiliary command, and further structured to block theactuating signal of the standard on/off circuit in response to theauxiliary command indicating that the moveable contact should not beelectrically coupled to the fixed contact. The auxiliary command mayinclude at least one command selected from the commands consisting of:an emergency shutdown command, a service event indicator, a maintenanceevent indicator, an accident indicator, a vehicle controller request,and a device protection request. The standard on/off circuit may includeone of a keyswitch voltage and a keyswitch indicator. The breaker/relayfurther may include a contact force spring operationally interposedbetween the armature and the moveable contact, such that in response tothe armature being in the second position, the contact force spring maybe at least partially compressed, and wherein the contact force springmay be configured such that a Lorentz force acting between the fixedcontact and the moveable contact further compresses the contact forcespring in response to a selected current value. The high current valuemay be lower than the selected current value. The moveable contact mayinclude a body extending away from the fixed contact, wherein the bodyof the moveable contact may be disposed within a plurality of splitterplates, and wherein the plurality of splitter plates may be at leastpartially disposed within a permanent magnet. The mobile application mayfurther include a charging circuit, and wherein the breaker/relay may befurther positioned on the charging circuit. The charging circuit mayinclude a quick charging circuit having a higher current throughputvalue than a rated current for operations of the electrical load. Theelectrical load may include at least one load selected from the loadsconsisting of: a motive power load, a regeneration load, a powertake-off load, an auxiliary device load, and an accessory device load.The mobile application may further include a second breaker/relaydisposed on the other of the high side or the low side of the powerstorage device. The power storage device may include a rechargeabledevice. The power storage device may include at least one deviceselected from the devices consisting of: a battery, a capacitor, and afuel cell.

In an aspect, a system may include a vehicle having a motive electricalpower circuit; a power distribution unit having a current protectioncircuit disposed in a motive electrical power path, the currentprotection circuit including a first leg of the current protectioncircuit including a breaker/relay, the breaker/relay including a fixedcontact electrically coupled to a motive power circuit for a mobileapplication; a moveable contact selectively electrically coupled to thefixed contact, wherein the moveable contact in a first position allowspower to flow through the motive power circuit, and the moveable contactin a second position does not allow power to flow through the motivepower circuit; and a physical opening response portion responsive to acurrent value in the motive power circuit, wherein the physical openingresponse portion may be configured to move the moveable contact to thesecond position in response to the current value exceeding a thresholdcurrent value; and a second leg of the current protection circuitelectrically coupled in parallel with the first leg of the currentprotection circuit, the second leg including a contactor. Inembodiments, the breaker/relay may include a first breaker/relay, andwherein the contactor may include a second breaker/relay. The second legfurther may include a thermal fuse in series with the contactor.

In an aspect, a system may include a vehicle having a motive electricalpower circuit; a power distribution unit having a current protectioncircuit disposed in a motive electrical power path, the currentprotection circuit including: a breaker/relay including a fixed contactelectrically coupled to a motive power circuit for a mobile application;a moveable contact selectively electrically coupled to the fixedcontact, wherein the moveable contact in a first position allows powerto flow through the motive power circuit, and the moveable contact in asecond position does not allow power to flow through the motive powercircuit; and a physical opening response portion responsive to a currentvalue in the motive power circuit, wherein the physical opening responseportion may be configured to move the moveable contact to the secondposition in response to the current value exceeding a threshold currentvalue; and a contactor in series with the breaker/relay.

In an aspect, a system may include a vehicle having a motive electricalpower path; a power distribution unit including a current protectioncircuit disposed in the motive electrical power path, the currentprotection circuit including breaker/relay, the breaker/relay including:a fixed contact electrically coupled to a motive power circuit for amobile application; a moveable contact selectively electrically coupledto the fixed contact, wherein the moveable contact in a first positionallows power to flow through the motive power circuit, and the moveablecontact in a second position does not allow power to flow through themotive power circuit; and a physical opening response portion responsiveto a current value in the motive power circuit, wherein the physicalopening response portion may be configured to move the moveable contactto the second position in response to the current value exceeding athreshold current value; a current source circuit electrically coupledto the breaker/relay and structured to inject a current across the fixedcontact; and a voltage determination circuit electrically coupled to thebreaker/relay and structured to determine at least one of an injectedvoltage amount and a contactor impedance value, wherein the voltagedetermination circuit may include a high pass filter having a cutofffrequency selected in response to a frequency of the injected current.In embodiments, the voltage determination circuit further may include abandpass filter having a bandwidth selected to bound the frequency ofthe injected current. The high pass filter may include an analoghardware filter. The high pass filter may include a digital filter. Thevoltage determination circuit may be further structured to determine thecontactor impedance value in response to an injected voltage drop. Thesystem may further include a contactor characterization circuitstructured to store one of a contactor resistance value and thecontactor impedance value, and wherein the contactor characterizationcircuit may be further structured to update the stored one of thecontactor resistance value and the contactor impedance value in responseto the contactor impedance value. The contactor characterization circuitmay be further structured to update the stored one of the contactorresistance value and the contactor impedance value by performing atleast one operation selected from the operations consisting of: updatinga value to the contactor impedance value; filtering a value using thecontactor impedance value as a filter input; rejecting the contactorimpedance value for a period of time or for a number of determinationsof the contactor impedance value; and updating a value by performing arolling average of a plurality of contactor impedance values over time.The power distribution unit further may include a plurality ofbreaker/relay devices disposed therein, and wherein the current sourcecircuit may be further electrically coupled to the plurality ofbreaker/relay devices, and to sequentially inject a current across eachfixed contact of the plurality of breaker/relay devices; and wherein thevoltage determination circuit may be further electrically coupled toeach of the plurality of breaker/relay devices, and further structuredto determine at least one of an injected voltage amount and a contactorimpedance value for each of the plurality of breaker/relay devices. Thecurrent source circuit may be further structured to sequentially injectthe current across each of the plurality of breaker/relay devices in aselected order of the breaker/relay devices. The current source circuitmay be further structured to adjust the selected order in response to atleast one of: a rate of change of a temperature of each of the fixedcontacts of the breaker/relay devices; an importance value of each ofthe breaker/relay devices; a criticality of each of the breaker/relaydevices; a power throughput of each of the breaker/relay devices; andone of a fault condition or a contactor health condition of each of thebreaker/relay devices. The current source circuit may be furtherstructured to adjust the selected order in response to one of a plannedduty cycle and an observed duty cycle of the vehicle. The current sourcecircuit may be further structured to sweep the injected current througha range of injection frequencies. The current source circuit may befurther structured to inject the current across the fixed contact at aplurality of injection frequencies. The current source circuit may befurther structured to inject the current across the fixed contact at aplurality of injection voltage amplitudes. The current source circuitmay be further structured to inject the current across the fixed contactat an injection voltage amplitude determined in response to a powerthroughput of the breaker/relay devices. The current source circuit maybe further structured to inject the current across the fixed contact atan injection voltage amplitude determined in response to a duty cycle ofthe vehicle.

In an aspect, a system may include a vehicle having a motive electricalpower path; a power distribution unit including a current protectioncircuit disposed in the motive electrical power path, the currentprotection circuit including breaker/relay, the breaker/relay includinga fixed contact electrically coupled to a motive power circuit for amobile application; a moveable contact selectively electrically coupledto the fixed contact, wherein the moveable contact in a first positionallows power to flow through the motive power circuit, and the moveablecontact in a second position does not allow power to flow through themotive power circuit; and a physical opening response portion responsiveto a current value in the motive power circuit, wherein the physicalopening response portion may be configured to move the moveable contactto the second position in response to the current value exceeding athreshold current value; a current source circuit electrically coupledto the breaker/relay and structured to inject a current across the fixedcontact; and a voltage determination circuit electrically coupled to thebreaker/relay and structured to determine an injected voltage amount anda contactor impedance value, wherein the voltage determination circuitmay be structured to perform a frequency analysis operation to determinethe injected voltage amount. In embodiments, the voltage determinationcircuit may be further structured to determine the injected voltageamount by determining an amplitude of a voltage across the fixed contactat a frequency of interest. The frequency of interest may be determinedin response to a frequency of the injected voltage. The current sourcecircuit may be further structured to sweep the injected current througha range of injection frequencies. The current source circuit may befurther structured to inject the current across the fixed contact at aplurality of injection frequencies. The current source circuit may befurther structured to inject the current across the fixed contact at aplurality of injection voltage amplitudes. The current source circuitmay be further structured to inject the current across the fixed contactat an injection voltage amplitude determined in response to a powerthroughput of the breaker/relay. The current source circuit may befurther structured to inject the current across the fixed contact at aninjection voltage amplitude determined in response to a duty cycle ofthe vehicle.

In an aspect, a multi-port power converter may include a housing mayinclude a plurality of ports structured to electrically interface to aplurality of loads, the plurality of loads having distinct electricalcharacteristics; a plurality of solid state components configured toprovide selected electrical power outputs and to accept selectedelectrical power inputs; and a plurality of solid state switchesconfigured to provide selected connectivity between the plurality ofsolid state components and the plurality of ports. In embodiments, theplurality of distinct electrical characteristics may be selected fromthe electrical characteristics consisting of: a DC voltage, an ACvoltage or voltage equivalent, a load power rating, a regenerative powerrating, a current rating, a current directionality, a response timecharacteristic, a frequency characteristic, and a phase characteristic.The plurality of ports may include at least two AC interface ports andat least three DC interface ports. The multi-port power converter mayfurther include a controller, the controller including a component bankconfiguration circuit structured to interpret a port electricalinterface description, the port electrical interface descriptionincluding a description of at least a portion of the distinct electricalcharacteristics; and a component bank implementation circuit structuredto provide solid switch states in response to the port electricalinterface description, and wherein the plurality of solid state switchesmay be responsive to the solid switch states. The controller further mayinclude a load/source drive description circuit structured to interpreta source/load drive characteristic, wherein the source/load drivecharacteristic may include at least one electrical characteristicrequirement of a load; and a load/source drive implementation circuitstructured to provide a component driver configuration in response tothe source/load drive characteristic. The multi-port power converter mayfurther include at least one of wherein the solid state switches may befurther responsive to the source/load drive characteristic; wherein agate driver controller may be responsive to the source/load drivecharacteristic; and wherein a requestor component for a gate drivercontroller may be responsive to the source/load drive characteristic.The plurality of loads having distinct electrical characteristics may bea superset of a plurality of loads having distinct electricalcharacteristics sufficient to encompass a selected class ofapplications, each application including at least one of: a vehicle, anoff-road vehicle, and a set of load types for a vehicle. The multi-portpower converter includes a sufficient number of solid state components,solid state switches, and ports, such that the multi-port powerconverter can provide the plurality of loads having distinct electricalcharacteristics for any member of the selected class of applications.The plurality of loads having distinct electrical characteristics may bea superset of a plurality of loads having distinct electricalcharacteristics sufficient to encompass a selected class ofapplications, each application including at least one of: a vehicle, anoff-road vehicle, and a set of load types for a vehicle. The multi-portpower converter may further include a first application of the selectedclass of applications having a first set of distinct electricalcharacteristics, wherein a second application of the selected class ofapplications has a second set of distinct electrical characteristics,wherein a first multi-port power converter supports the firstapplication, wherein a second multi-port power converter supports thesecond application, and wherein the first multi-port power converter andthe second multi-port power converter have identical ports, solid statecomponents, and solid state switches. The first multi-port powerconverter and the second multi-port power converter have distinct solidswitch states. The plurality of loads having distinct electricalcharacteristics may be a superset of a plurality of loads havingdistinct electrical characteristics sufficient to encompass a selectedclass of applications, each application including at least one of: avehicle, an off-road vehicle, and a set of load types for a vehicle. Themulti-port power converter may further include a first application ofthe selected class of applications having a first set of distinctelectrical characteristics, wherein a second application of the selectedclass of applications has a second set of distinct electricalcharacteristics, wherein a first multi-port power converter supports thefirst application, wherein a second multi-port power converter supportsthe second application, and wherein the first multi-port power converterand the second multi-port power converter have identical ports, solidstate components, and solid state switches. The first multi-port powerconverter and the second multi-port power converter have distinct solidswitch states and distinct component driver configurations.

In an aspect, a power converter have a plurality of ports including aplurality of solid state components configured to provide selectedelectrical power outputs and to accept selected electrical power inputs;a plurality of solid state switches electrically interposed between theplurality of ports and the plurality of solid state components, whereinthe plurality of solid state switches may be configured to selectivelycouple sets of the plurality of solid state components to the pluralityof ports; and a controller, including: a component bank configurationcircuit structured to interpret a port electrical interface description,the port electrical interface description including a description ofelectrical characteristics for one of the plurality of ports; and acomponent bank implementation circuit structured to provide solid switchstates in response to the port electrical interface description, andwherein the plurality of solid state switches may be responsive to thesolid switch states. In embodiments, the controller further may includea load/source drive description circuit structured to interpret asource/load drive characteristic, wherein the source/load drivecharacteristic may include at least one electrical characteristicrequirement of a load; and a load/source drive implementation circuitstructured to provide a component driver configuration in response tothe source/load drive characteristic. The component bank implementationcircuit further provides the solid switch states in response to thesource/load drive characteristic; and wherein a gate driver controllerfor at least one of the solid state components may be responsive to thesource/load drive characteristic. Each of the solid state components mayinclude at least one of an inverter or a DC/DC converter. The componentbank configuration circuit may be further structured to interpret a portconfiguration service request value, and wherein the component bankimplementation circuit further provides the solid switch states inresponse to the port configuration service request value. The componentbank configuration circuit may be further structured to interpret a portconfiguration definition value, and wherein the component bankimplementation circuit further provides the solid switch states inresponse to the port configuration definition value.

In an aspect, a method may include interpreting a port electricalinterface description, the port electrical interface descriptionincluding a description of electrical characteristics for at least oneof a plurality of ports of a power converter for an electric mobileapplication; and providing solid switch states in response to the portelectrical interface description, thereby configuring at least one of anAC inverter or a DC/DC converter to provide power to the at least one ofthe plurality of ports according to the port electrical interfacedescription. In embodiments, the method may further include interpretingthe port electrical interface description during run time operations ofthe electric mobile application. The method may further includeinterpreting the port electrical interface description from a servicetool communicating with a controller of the power converter. The methodmay further include interpreting the port electrical interfacedescription from a manufacturing tool in communicating with a controllerof the power converter. Providing the solid state switch states may beperformed as a remanufacture operation for the power converter.Providing the solid state switch states may be performed as an operationselected from the operations consisting of: an upfit operation for theelectric mobile application, an application change operation for theelectric mobile application, and a refit operation for the electricmobile application. The method may further include interpreting asource/load drive characteristic for at least one of the plurality ofports of the power converter, wherein the source/load drivecharacteristic may include at least one electrical characteristicrequirement of a load, and providing a component driver configuration inresponse to the source/load drive characteristic. The method may furtherinclude interpreting the source/load drive characteristic during runtime operations of the electric mobile application. The method mayfurther include interrogating at least one load electrically coupled tothe at least one port of the power converter, and interpreting thesource/load drive characteristic in response to the interrogating. Themethod may further include interpreting the source/load drivecharacteristic from a service tool communicating with a controller ofthe power converter. The method may further include interpreting thesource/load drive characteristic from a manufacturing tool incommunicating with a controller of the power converter. Providing thecomponent driver configuration may be performed as a remanufactureoperation for the power converter. The providing the component driverconfiguration may be performed as an operation selected from theoperations consisting of: an upfit operation for the electric mobileapplication, an application change operation for the electric mobileapplication, and a refit operation for the electric mobile application.

In an aspect, a method may include providing a power converter having aplurality of ports; determining an electrical interface description forat least one power source of an electric mobile application and at leastone electrical load of the electric mobile application; providing solidswitch states in response to the electrical interface description,thereby configuring at least one of an AC inverter or a DC/DC converterto provide or accept power to the at least one of the plurality of portsaccording to the port electrical interface description; and installingthe power converter into the electric mobile application. Inembodiments, the method may further include determining which ports ofthe power converter are to be coupled to the at least one power sourceand the at least one electrical load, and wherein providing the solidswitch states may include configuring electrical characteristics of thedetermined ports according to the port electrical interface description.The method may further include a plurality of the electric loads,wherein a first one of the electrical loads may include an AC load, andwherein a second one of the electrical loads may include a DC load. Themethod may further include a plurality of the power sources, wherein afirst one of the power sources may include a DC source at a firstvoltage, and wherein a second one of the power sources may include a DCsource at a second voltage. The method may further include determining asource/load drive characteristic for at least one of electric loads ofthe electric mobile application, and providing a component driverconfiguration in response to the source/load drive characteristic. Thecomponent driver configuration may include a gate driver controller foran inverter component coupled to one of the plurality of portscorresponding to the at least one of the electric loads of the electricmobile application. The method may further include coupling a coolantinlet port and a coolant outlet port to a cooling system of the electricmobile application.

In an aspect, an integrated inverter assembly may include a main coverand an opposing back cover; a coolant channel disposed between a coolantchannel cover and a coolant channel separating body; wherein powerelectronics of the inverter assembly may be thermally coupled to thecoolant channel; and wherein at least one of a coolant inlet or acoolant outlet of the coolant channel may include a quick connectorwithout a locking element. In embodiments, the quick connector furthermay include a fir tree hose coupling disposed on an outer housing wallof the quick connector. The coolant channel separating body further mayinclude an integrated hose nipple configured to couple with the quickconnector. The inverter assembly may further include a hose configuredto couple to the integrated hose nipple at a first end, and to the quickconnector at a second end. The hose may include a baffled hose.

In an aspect, an integrated inverter assembly may include a main coverand an opposing back cover; a plurality of IGBTs, each of the pluralityof IGBTs configured to provide at least one phase of AC power to amotor; and a potted DC link capacitor operationally disposed between theIGBTs and a DC power source, and wherein the potted DC link capacitormay include a bus bar, a common-mode choke, and a capacitor disposed ina housing of the potted DC link capacitor. In embodiments, the inverterassembly may further include a first welded connection between thepotted DC link capacitor and each of the IGBTs, and a second weldedconnection between each of the IGBTs and an AC motor connector of theinverter assembly. The AC motor connector may include a plurality of ACblades. Each of the plurality of AC blades may extend through a foamseal, thereby forming the AC motor connector. The potted DC linkcapacitor may be thermally coupled to an integral coolant channel of theinverter assembly. The potted DC link capacitor may project from one ofthe main cover and the opposing back cover.

In an aspect, an integrated inverter assembly may include a main coverand an opposing back cover; a coolant channel disposed between a coolantchannel cover and a coolant channel separating body; and wherein powerelectronics of the inverter assembly may be thermally coupled to thecoolant channel. In embodiments, the coolant channel separating body maybe friction-stir welded to each of the main cover and the coolantchannel separating body. The assembly may further include a secondcoolant channel, wherein the coolant channel may be disposed on a firstside of the coolant channel separating body, and wherein the secondcoolant channel may be disposed on a second side of the coolant channelseparating body. The assembly may further include where the main covermay be cast, the coolant channel separating body may be forged, and thecoolant channel cover may be stamped. The assembly may further includewherein the main cover defines a plurality of coupling threaded bores,and wherein the back cover defines a corresponding plurality of couplingthreaded bores. The corresponding plurality of coupling threaded boresfurther each include an unthreaded pilot portion of the bores, andwherein the unthreaded pilot portion of the bores may include a firstheight, wherein a plurality of coupling screws each include a threadedportion having a second height, and wherein the first height may begreater than the second height. The main cover further defines anarrowed portion of each of the plurality of coupling threaded bores,and wherein each of the plurality of coupling screws further may includea thin neck portion, and wherein the threaded portion of each of theplurality of coupling screws has a diameter greater than the thin neckportion. The assembly may further include a cure-in-place-gasketpositioned between the main cover and the back cover. The assembly mayfurther include wherein the cure-in-place-gasket may be dispensed on themain cover. At least one of the main cover and the back cover mayinclude a ledge having a selected height such that thecure-in-place-gasket has a selected compression when the main cover maybe coupled to the back cover.

In an aspect, a method may include operating a motor for an electricmobile application; determining a motor temperature value in response toat least one parameter selected from the parameters consisting of: apower throughput of the motor; a voltage input value to the motor; and acurrent input value to the motor; interpreting a sensed motortemperature value for the motor; and adjusting an operating parameterfor the motor in response to the motor temperature value and the sensedmotor temperature value. In embodiments, the method may further includeusing a combination of the motor temperature value and the sensed motortemperature value to determine a motor effective temperature value, andwherein the adjusting the operating parameter may be further in responseto the motor effective temperature value. The method may further includedetermining a first reliability value for the motor temperature value inresponse to a first operating condition for the motor, determining asecond reliability value for the sensed motor temperature value inresponse to a second operating condition for the motor, and whereindetermining the motor effective temperature value may be further inresponse to the first reliability value and the second reliabilityvalue. The method may further include using the sensed motor temperaturevalue as the motor effective temperature value in response to the secondreliability value exceeding a threshold value. The sensed motortemperature value for the motor may include a sensed temperature from afirst component within the motor, the method may further includeapplying a correction to the sensed motor temperature value to determinea second sensed temperature value including an estimated temperature fora second component within the motor, and further using the second sensedtemperature value to determine the motor effective temperature value.The method may further include applying a hot spot adjustment correctionto the sensed motor temperature value, and further using the adjustedsensed motor temperature value to determine the motor effectivetemperature value. The method may further include determining the firstreliability value in response to at least one operating conditionselected from the operating conditions consisting of: a power throughputof the motor; a rate of change of power throughput of the motor; adefined range value for a model used to determine the motor temperaturevalue; and a rate of change of one of the motor temperature value or theeffective motor temperature value. The method may further includedetermining the second reliability value in response to at least oneoperating condition selected from the operating conditions consistingof: a power throughput of the motor; a rate of change of powerthroughput of the motor; a defined range value for a temperature sensorproviding the sensed motor temperature value; a response time for atemperature sensor providing the sensed motor temperature value; and afault condition for a temperature sensor providing the sensed motortemperature value. The method may further include using one or the otherof the motor temperature value and the sensed motor temperature value asthe motor effective temperature value. The method may further includemixing the motor temperature value, the sensed motor temperature value,and a previous value of the motor effective temperature value todetermine the motor effective temperature value. The method may furtherinclude applying a low-pass filter to the motor effective temperaturevalue. The adjusting the operating parameter may include at least oneoperation selected from the operations consisting of: adjusting a ratingof the motor; adjusting a rating of a load of the electric mobileapplication; adjusting an active cooling amount for the motor; andadjusting an operating space of the motor based on an efficiency map ofthe motor.

In an aspect, an apparatus may include a motor control circuitstructured to operate a motor for an electric mobile application; anoperating conditions circuit structured to interpret a sensed motortemperature value for the motor, and further structured to interpret atleast one parameter selected from the parameters consisting of: a powerthroughput of the motor; a voltage input value to the motor; a currentinput value to the motor; an ambient temperature value; and an activecooling amount for the motor; a motor temperature determination circuitstructured to determine a motor temperature value in response to the atleast one of the a power throughput of the motor; a voltage input valueto the motor; a current input value to the motor; an ambient temperaturevalue; and an active cooling amount for the motor; and determine a motoreffective temperature value in response to the motor temperature valueand the sensed motor temperature value; and wherein the motor controlcircuit may be further structured to adjust at least one operatingparameter for the motor in response to the motor effective temperaturevalue. In embodiments, the motor temperature determination circuit maybe further structured to determine a first reliability value for themotor temperature value in response to a first operating condition forthe motor; determine a second reliability value for the sensed motortemperature value in response to a second operating condition for themotor; and determine the motor effective temperature value further inresponse to the first reliability value and the second reliabilityvalue. The motor temperature determination circuit may be furtherstructured to use the sensed motor temperature value as the motoreffective temperature value in response to the second reliability valueexceeding a threshold value. The motor temperature determination circuitmay be further structured to apply one of an offset component adjustmentor a hot spot adjustment to the sensed motor temperature value; anddetermine the motor effective temperature value further in response tothe adjusted sensed motor temperature value. The motor temperaturedetermination circuit may be further structured to determine the firstreliability value in response to at least one operating conditionselected from the operating conditions consisting of: the powerthroughput of the motor; a rate of change of power throughput of themotor; a defined range value for a model used to determine the motortemperature value; and a rate of change of one of the motor temperaturevalue or the effective motor temperature value. The motor temperaturedetermination circuit may be further structured to determine the secondreliability value in response to at least one operating conditionselected from the operating conditions consisting of: the powerthroughput of the motor; a rate of change of power throughput of themotor; a defined range value for a temperature sensor providing thesensed motor temperature value; a response time for a temperature sensorproviding the sensed motor temperature value; and a fault condition fora temperature sensor providing the sensed motor temperature value. Themotor control circuit may be further structured to adjust at least oneoperating parameter selected from the operating parameters consistingof: a rating of the motor; a rating of a load of the electric mobileapplication; the active cooling amount for the motor; and an operatingspace of the motor based on an efficiency map of the motor.

In an aspect, a system may include an electric mobile application havinga motor and an inverter, wherein the inverter may include a plurality ofdriving elements for the motor; a controller, including a motor controlcircuit structured to provide driver commands, and wherein the pluralityof driving elements may be responsive to the driver commands; anoperating conditions circuit structured to interpret a motor performancerequest value including at least one of a power, speed, or torquerequest for the motor; a driver efficiency circuit structured tointerpret a driver activation value for each of the plurality of drivingelements of the inverter in response to the motor performance requestvalue; and wherein the motor control circuit may be further structuredto provide the driver commands to de-activate at least one of theplurality of driving elements for the motor in response to the driveractivation value for each of the plurality of driving elements of theinverter. In embodiments, the motor may include a three-phase AC motor,wherein the plurality of driving elements include six driving elements,and wherein the driver efficiency circuit provides the driver activationvalue to de-activate three of the six driving elements in response tothe motor performance request value being below a threshold value.

In an aspect, a method may include providing driver commands to aplurality of driving elements of an inverter electrically coupled to amotor for an electric mobile application; interpreting a motorperformance request value including at least one of a power, speed, ortorque request for the motor; interpreting a driver activation value foreach of the plurality of driving elements of the inverter in response tothe motor performance request value; and providing the driver commandsto de-activate at least one of the plurality of driving elements for themotor in response to the driver activation value for each of theplurality of driving elements of the inverter. In embodiments, themethod may further include providing the driver commands to de-activatethree out of six total driving elements in response to the motorperformance request value being below a threshold value. The method mayfurther include de-activating a first three out of the six total drivingelements during a first de-activation operation, and de-activating asecond three out of the six total driving elements during a secondde-activation operation.

In an aspect, a system may include an electric mobile application havinga plurality of electric motors, each one of the plurality of electricmotors operationally coupled to a corresponding one of a plurality ofelectric loads; a controller, including an application load circuitstructured to interpret an application performance request value; aperformance servicing circuit structured to determine a plurality ofmotor commands in response to a motor capability description and theapplication performance request value; and a motor control circuitstructured to provide the plurality of motor commands to correspondingmotors of the plurality of electric motors; and wherein the plurality ofelectric motors may be responsive to the plurality of motor commands. Inembodiments, the performance servicing circuit may be further structuredto determine the plurality of motor commands in response to one of afault condition or a failure condition for at least one of the pluralityof electric motors. The performance servicing circuit may be furtherstructured to provide the plurality of motor commands to meet theapplication performance request value by at least partiallyredistributing load requirements from one of the plurality of electricmotors having the fault condition or the failure condition, to at leastone of the plurality of electric motors having available performancecapacity. The performance servicing circuit may be further structured toderate one of the plurality of electric motors in response to the one ofthe fault condition or the failure condition. The system may furtherinclude a first data store associated with a first one of the pluralityof electric motors, a second data store associated with a second one ofthe plurality of electric motors, and wherein the controller further mayinclude a data management circuit structured to command at least partialdata redundancy between the first data store and the second data store.The at least partial data redundancy may include at least one data valueselected from the data values consisting of: a fault value, a systemstate, and a learning component value. The data management circuit maybe further structured to command the at least partial data redundancy inresponse to one of a fault condition or a failure condition related toat least one of: one of the plurality of electric motors, or a localcontroller operationally coupled to one of the plurality of electricmotors. The performance servicing circuit may be further structured todetermine the plurality of motor commands in response to the one of thefault condition or the failure condition, and further in response todata from the at least partial data redundancy. The performanceservicing circuit may be further structured to suppress an operatornotification of one of a fault condition or a failure condition inresponse to a performance capability of the plurality of electric motorsbeing capable of delivering the application performance request value.The performance servicing circuit may be further structured tocommunicate the suppressed operator notification to at least one of aservice tool or an external controller, wherein the external controllermay be at least intermittently communicatively coupled to thecontroller. The performance servicing circuit may be further structuredto adjust the application performance request value in response to aperformance capability of the plurality of electric motors beingincapable of delivering the application performance request value.

In an aspect, a method may include interpreting an applicationperformance request value; determining a plurality of motor commands inresponse to a motor capability description and the applicationperformance request value; and providing the plurality of motor commandsto corresponding motors of a plurality of electric motors operationallycoupled to corresponding ones of a plurality of electric loads of anelectric mobile application. In embodiments, the method may furtherinclude determining the plurality of motor commands in response to oneof a fault condition or a failure condition for at least one of theplurality of electric motors. The method may further include providingthe plurality of motor commands to meet the application performancerequest value by at least partially redistributing load requirementsfrom one of the plurality of electric motors having the fault conditionor the failure condition, to at least one of the plurality of electricmotors having available performance capacity. The method may furtherinclude derating one of the plurality of electric motors in response tothe one of the fault condition or the failure condition. The method mayfurther include commanding at least partial data redundancy between afirst data store associated with a first one of the plurality ofelectric motors and a second data store associated with a second one ofthe plurality of electric motors. The at least partial data redundancymay include at least one data value selected from the data valuesconsisting of: a fault value, a system state, and a learning componentvalue. The method may further include commanding the at least partialdata redundancy in response to one of a fault condition or a failurecondition related to at least one of: one of the plurality of electricmotors, or a local controller operationally coupled to one of theplurality of electric motors. The method may further include determiningthe plurality of motor commands in response to the one of the faultcondition or the failure condition, and further in response to data fromthe at least partial data redundancy. One of a fault condition or afailure condition may relate to a first local controller operationallycoupled to one of the plurality of electric motors, the method mayfurther include controlling the one of the plurality of electric motorswith a second local controller communicatively coupled to the one of theplurality of electric motors. The method may further include suppressingan operator notification of one of a fault condition or a failurecondition in response to a performance capability of the plurality ofelectric motors being capable of delivering the application performancerequest value. The method may further include communicating thesuppressed operator notification to at least one of a service tool or anexternal controller, wherein the external controller may be at leastintermittently communicatively coupled to a controller of the electricmobile application. The method may further include adjusting theapplication performance request value in response to a performancecapability of the plurality of electric motors being incapable ofdelivering the application performance request value.

In an aspect, a system may include a vehicle having a motive electricalpower path; a power distribution unit having a current protectioncircuit disposed in the motive electrical power path, the currentprotection circuit including: a first leg of the current protectioncircuit including a pyro-fuse; a second leg of the current protectioncircuit including a thermal fuse; and wherein the first leg and thesecond leg may be coupled in a parallel arrangement; a controller mayinclude a current detection circuit structured to determine a currentflow through the motive electrical power path; and a pyro-fuseactivation circuit structured to provide a pyro-fuse activation commandin response to the current flow exceeding a threshold current flowvalue; wherein the pyro-fuse may be responsive to the pyro-fuseactivation command; and a fuse management circuit structured to providea switch activation command in response to the current flow, wherein thesolid state switch may be responsive to the switch activation command.In embodiments, a first resistance through the first leg and a secondresistance through the second leg may be configured such that aresulting current through the second leg after the pyro-fuse activatesmay be sufficient to activate the thermal fuse. The system may furtherinclude a contactor coupled to the current protection circuit, whereinthe contactor in the open position disconnects one of the currentprotection circuit or the second leg of the current protection circuit.

In an aspect, a system may include a vehicle having a motive electricalpower path; a power distribution unit having a current protectioncircuit disposed in the motive electrical power path, the currentprotection circuit including: a first leg of the current protectioncircuit including a thermal fuse, a second leg of the current protectioncircuit including a solid state switch, wherein the first leg and thesecond leg may be coupled in a parallel arrangement, and a thermal fuseand a contactor in a series arrangement with the thermal fuse; acontroller may include a current detection circuit structured todetermine a current flow through the motive electrical power path; and afuse management circuit structured to provide a switch activationcommand in response to the current flow; wherein the solid state switchmay be responsive to the switch activation command; a high voltage powerinput coupling including a first electrical interface for a high voltagepower source; and a high voltage power output coupling including asecond electrical interface for a motive power load; wherein the currentprotection circuit electrically couples the high voltage power input tothe high voltage power output, and wherein the current protectioncircuit may be at least partially disposed in a laminated layer of thepower distribution unit, the laminated layer including an electricallyconductive flow path disposed two electrically insulating layers. Inembodiments, the system may further include a contactor coupled to thecurrent protection circuit, wherein the contactor in the open positiondisconnects one of the current protection circuit or the second leg ofthe current protection circuit. The current protection circuit mayinclude a motive power bus bar disposed in the laminated layer of thepower distribution unit.

In an aspect, an integrated inverter assembly with power converterhaving a plurality of ports may include a main cover and an opposingback cover; a coolant channel disposed between a coolant channel coverand a coolant channel separating body; wherein power electronics of theinverter assembly may be thermally coupled to the coolant channel;wherein at least one of a coolant inlet or a coolant outlet of thecoolant channel includes a quick connector without a locking element; aplurality of solid state components configured to provide selectedelectrical power outputs and to accept selected electrical power inputs;a plurality of solid state switches electrically interposed between theplurality of ports and the plurality of solid state components, whereinthe plurality of solid state switches may be configured to selectivelycouple sets of the plurality of solid state components to the pluralityof ports; and a controller may include a component bank configurationcircuit structured to interpret a port electrical interface description,the port electrical interface description including a description ofelectrical characteristics for one of the plurality of ports; and acomponent bank implementation circuit structured to provide solid switchstates in response to the port electrical interface description, andwherein the plurality of solid state switches may be responsive to thesolid switch states. In embodiments, the quick connector may furtherinclude a fir tree hose coupling disposed on an outer housing wall ofthe quick connector. The controller may further include a load/sourcedrive description circuit structured to interpret a source/load drivecharacteristic, wherein the source/load drive characteristic includes atleast one electrical characteristic requirement of a load; and aload/source drive implementation circuit structured to provide acomponent driver configuration in response to the source/load drivecharacteristic.

In an aspect, an integrated inverter assembly may include a main coverand an opposing back cover; a coolant channel disposed between a coolantchannel cover and a coolant channel separating body; wherein powerelectronics of the inverter assembly may be thermally coupled to thecoolant channel; wherein at least one of a coolant inlet or a coolantoutlet of the coolant channel includes a quick connector without alocking element; a plurality of IGBTs, each of the plurality of IGBTsconfigured to provide at least one phase of AC power to a motor; and apotted DC link capacitor operationally disposed between the IGBTs and aDC power source, and wherein the potted DC link capacitor includes a busbar, a common-mode choke, and a capacitor disposed in a housing of thepotted DC link capacitor. In embodiments, the quick connector mayfurther include a fir tree hose coupling disposed on an outer housingwall of the quick connector. The inverter assembly may further include afirst welded connection between the potted DC link capacitor and each ofthe IGBTs, and a second welded connection between each of the IGBTs andan AC motor connector of the inverter assembly.

In an aspect, a system may include an electric mobile application havinga motor and an inverter, wherein the inverter includes a plurality ofdriving elements for the motor; a controller may include a motor controlcircuit structured to provide driver commands, and wherein the pluralityof driving elements may be responsive to the driver commands; anoperating conditions circuit structured to interpret a motor performancerequest value including at least one of a power, speed, or torquerequest for the motor; a driver efficiency circuit structured tointerpret a driver activation value for each of the plurality of drivingelements of the inverter in response to the motor performance requestvalue; wherein the motor control circuit may be further structured toprovide the driver commands to de-activate at least one of the pluralityof driving elements for the motor in response to the driver activationvalue for each of the plurality of driving elements of the inverter; anda breaker/relay including: a fixed contact electrically coupled to amotive power circuit; a moveable contact selectively electricallycoupled to the fixed contact, wherein the moveable contact in a firstposition allows power to flow through the motive power circuit, and themoveable contact in a second position does not allow power to flowthrough the motive power circuit; and a physical opening responseportion responsive to a current value in the motive power circuit,wherein the physical opening response portion may be configured to movethe moveable contact to the second position in response to the currentvalue exceeding a threshold current value. In embodiments, the motor mayinclude a three-phase AC motor, wherein the plurality of drivingelements include six driving elements, and wherein the driver efficiencycircuit provides the driver activation value to de-activate three of thesix driving elements in response to the motor performance request valuebeing below a threshold value. The fixed contact may include a firstfixed contact, the breaker/relay further including a second fixedcontact, wherein the moveable contact includes a first moveable contactcorresponding to the first fixed contact, the breaker/relay furtherincluding a second moveable contact corresponding to the second fixedcontact, and a bus bar electrically coupling the first moveable contactto the second moveable contact.

In an aspect, a system may include an electric mobile application havinga plurality of electric motors, each one of the plurality of electricmotors operationally coupled to a corresponding one of a plurality ofelectric loads; a controller may include an application load circuitstructured to interpret an application performance request value; aperformance servicing circuit structured to determine a plurality ofmotor commands in response to a motor capability description and theapplication performance request value; and a motor control circuitstructured to provide the plurality of motor commands to correspondingmotors of the plurality of electric motors; and wherein the plurality ofelectric motors may be responsive to the plurality of motor commands; amulti-port power converter may include a housing including a pluralityof ports structured to electrically interface to a plurality of loads,the plurality of loads having distinct electrical characteristics; aplurality of solid state components configured to provide selectedelectrical power outputs and to accept selected electrical power inputs;and a plurality of solid state switches configured to provide selectedconnectivity between the plurality of solid state components and theplurality of ports. In embodiments, the performance servicing circuitmay be further structured to determine the plurality of motor commandsin response to one of a fault condition or a failure condition for atleast one of the plurality of electric motors. The plurality of distinctelectrical characteristics may be selected from the electricalcharacteristics consisting of: a DC voltage, an AC voltage or voltageequivalent, a load power rating, a regenerative power rating, a currentrating, a current directionality, a response time characteristic, afrequency characteristic, and a phase characteristic.

In an aspect, a system may include an electric mobile application havinga plurality of electric motors, each one of the plurality of electricmotors operationally coupled to a corresponding one of a plurality ofelectric loads; a controller may include an application load circuitstructured to interpret an application performance request value; aperformance servicing circuit structured to determine a plurality ofmotor commands in response to a motor capability description and theapplication performance request value; a motor control circuitstructured to provide the plurality of motor commands to correspondingmotors of the plurality of electric motors; wherein the plurality ofelectric motors may be responsive to the plurality of motor commands; ahousing; a breaker/relay device positioned in the housing, wherein thebreaker/relay device may be configured to interrupt a motive powercircuit for an electrical vehicle system, where the housing may bedisposed on the electrical vehicle system; wherein the breaker/relaydevice includes a physical opening response portion responsive to afirst current value in the motive power circuit, and a controlledopening response portion responsive to a second current value in themotive power circuit; and a precharge circuit electrically coupled inparallel to the breaker/relay device. In embodiments, the performanceservicing circuit may be further structured to determine the pluralityof motor commands in response to one of a fault condition or a failurecondition for at least one of the plurality of electric motors. Thefirst current value may be greater than the second current value.

In an aspect, a system may include an electric mobile application havinga plurality of electric motors, each one of the plurality of electricmotors operationally coupled to a corresponding one of a plurality ofelectric loads; a controller may include an application load circuitstructured to interpret an application performance request value; aperformance servicing circuit structured to determine a plurality ofmotor commands in response to a motor capability description and theapplication performance request value; and a motor control circuitstructured to provide the plurality of motor commands to correspondingmotors of the plurality of electric motors; wherein the plurality ofelectric motors may be responsive to the plurality of motor commands;and a multi-port power converter may include a housing including aplurality of ports structured to electrically interface to a pluralityof loads, the plurality of loads having distinct electricalcharacteristics; a plurality of solid state components configured toprovide selected electrical power outputs and to accept selectedelectrical power inputs; and a plurality of solid state switchesconfigured to provide selected connectivity between the plurality ofsolid state components and the plurality of ports. In embodiments, theperformance servicing circuit may be further structured to determine theplurality of motor commands in response to one of a fault condition or afailure condition for at least one of the plurality of electric motors.The plurality of distinct electrical characteristics may be selectedfrom the electrical characteristics consisting of: a DC voltage, an ACvoltage or voltage equivalent, a load power rating, a regenerative powerrating, a current rating, a current directionality, a response timecharacteristic, a frequency characteristic, and a phase characteristic.

In an aspect, a system may include an electric mobile application havinga plurality of electric motors, each one of the plurality of electricmotors operationally coupled to a corresponding one of a plurality ofelectric loads; a controller may include an application load circuitstructured to interpret an application performance request value; aperformance servicing circuit structured to determine a plurality ofmotor commands in response to a motor capability description and theapplication performance request value; and a motor control circuitstructured to provide the plurality of motor commands to correspondingmotors of the plurality of electric motors; wherein the plurality ofelectric motors may be responsive to the plurality of motor commands; abreaker/relay may include a plurality of fixed contacts electricallycoupled electric load circuits for a mobile application; a plurality ofmoveable contacts, each moveable contact selectively electricallycoupled to a corresponding one of the plurality of fixed contacts; aplurality of armatures each operationally coupled to a corresponding oneof the moveable contacts, such that each armature in a first positionprevents electrical coupling between the corresponding moveable contactand the corresponding fixed contact, and each armature in a secondposition allows electrical coupling between the corresponding moveablecontact and the corresponding fixed contact; and a current responsecircuit structured to determine a current in each of the electric loadcircuits, and further structured to provide an armature command to openthe corresponding one of the moveable contacts in response to thecurrent in the corresponding electrical load circuit indicating a highcurrent value. In embodiments, the performance servicing circuit may befurther structured to determine the plurality of motor commands inresponse to one of a fault condition or a failure condition for at leastone of the plurality of electric motors. The system may further includea plurality of biasing members each operationally coupled to acorresponding one of the plurality of moveable contacts, and configuredto bias the corresponding one of the plurality of armatures into one ofthe first position or the second position.

In an aspect, a system may include an electric mobile application havinga plurality of electric motors, each one of the plurality of electricmotors operationally coupled to a corresponding one of a plurality ofelectric loads; a controller may include an application load circuitstructured to interpret an application performance request value; aperformance servicing circuit structured to determine a plurality ofmotor commands in response to a motor capability description and theapplication performance request value; and a motor control circuitstructured to provide the plurality of motor commands to correspondingmotors of the plurality of electric motors; wherein the plurality ofelectric motors may be responsive to the plurality of motor commands; amulti-port power converter may include a housing including a pluralityof ports structured to electrically interface to a plurality of loads,the plurality of loads having distinct electrical characteristics; aplurality of solid state components configured to provide selectedelectrical power outputs and to accept selected electrical power inputs;and a plurality of solid state switches configured to provide selectedconnectivity between the plurality of solid state components and theplurality of ports. In embodiments, the performance servicing circuitmay be further structured to determine the plurality of motor commandsin response to one of a fault condition or a failure condition for atleast one of the plurality of electric motors. The plurality of distinctelectrical characteristics may be selected from the electricalcharacteristics consisting of: a DC voltage, an AC voltage or voltageequivalent, a load power rating, a regenerative power rating, a currentrating, a current directionality, a response time characteristic, afrequency characteristic, and a phase characteristic.

In an aspect, a system may include an electric mobile application havinga plurality of electric motors, each one of the plurality of electricmotors operationally coupled to a corresponding one of a plurality ofelectric loads; a controller may include an application load circuitstructured to interpret an application performance request value; aperformance servicing circuit structured to determine a plurality ofmotor commands in response to a motor capability description and theapplication performance request value; and a motor control circuitstructured to provide the plurality of motor commands to correspondingmotors of the plurality of electric motors; wherein the plurality ofelectric motors may be responsive to the plurality of motor commands; abreaker/relay may include a fixed contact electrically coupled to amotive power circuit for a mobile application; a moveable contactselectively electrically coupled to the fixed contact, wherein themoveable contact in a first position allows power to flow through themotive power circuit, and the moveable contact in a second position doesnot allow power to flow through the motive power circuit; and a physicalopening response portion responsive to a current value in the motivepower circuit, wherein the physical opening response portion may beconfigured to move the moveable contact to the second position inresponse to the current value exceeding a threshold current value. Inembodiments, the performance servicing circuit may be further structuredto determine the plurality of motor commands in response to one of afault condition or a failure condition for at least one of the pluralityof electric motors. The fixed contact may include a first fixed contact,the breaker/relay further including a second fixed contact, wherein themoveable contact includes a first moveable contact corresponding to thefirst fixed contact, the breaker/relay further including a secondmoveable contact corresponding to the second fixed contact, and a busbar electrically coupling the first moveable contact to the secondmoveable contact.

In an aspect, a system may include an electric mobile application havinga plurality of electric motors, each one of the plurality of electricmotors operationally coupled to a corresponding one of a plurality ofelectric loads; a controller may include an application load circuitstructured to interpret an application performance request value; aperformance servicing circuit structured to determine a plurality ofmotor commands in response to a motor capability description and theapplication performance request value; and a motor control circuitstructured to provide the plurality of motor commands to correspondingmotors of the plurality of electric motors; wherein the plurality ofelectric motors may be responsive to the plurality of motor commands; amulti-port power converter may include a housing including a pluralityof ports structured to electrically interface to a plurality of loads,the plurality of loads having distinct electrical characteristics; aplurality of solid state components configured to provide selectedelectrical power outputs and to accept selected electrical power inputs;and a plurality of solid state switches configured to provide selectedconnectivity between the plurality of solid state components and theplurality of ports. In embodiments, the performance servicing circuitmay be further structured to determine the plurality of motor commandsin response to one of a fault condition or a failure condition for atleast one of the plurality of electric motors. The plurality of distinctelectrical characteristics may be selected from the electricalcharacteristics consisting of: a DC voltage, an AC voltage or voltageequivalent, a load power rating, a regenerative power rating, a currentrating, a current directionality, a response time characteristic, afrequency characteristic, and a phase characteristic.

In an aspect, an integrated inverter assembly may include a main coverand an opposing back cover; a coolant channel disposed between a coolantchannel cover and a coolant channel separating body; wherein powerelectronics of the inverter assembly may be thermally coupled to thecoolant channel; wherein at least one of a coolant inlet or a coolantoutlet of the coolant channel includes a quick connector without alocking element; and a multi-port power converter may include a housingincluding a plurality of ports structured to electrically interface to aplurality of loads, the plurality of loads having distinct electricalcharacteristics; a plurality of solid state components configured toprovide selected electrical power outputs and to accept selectedelectrical power inputs; and a plurality of solid state switchesconfigured to provide selected connectivity between the plurality ofsolid state components and the plurality of ports. In embodiments, theplurality of distinct electrical characteristics may be selected fromthe electrical characteristics consisting of: a DC voltage, an ACvoltage or voltage equivalent, a load power rating, a regenerative powerrating, a current rating, a current directionality, a response timecharacteristic, a frequency characteristic, and a phase characteristic.The quick connector may further include a fir tree hose couplingdisposed on an outer housing wall of the quick connector.

In an aspect, an integrated inverter assembly may include a main coverand an opposing back cover; a plurality of IGBTs, each of the pluralityof IGBTs configured to provide at least one phase of AC power to amotor; a potted DC link capacitor operationally disposed between theIGBTs and a DC power source, and wherein the potted DC link capacitorincludes a bus bar, a common-mode choke, and a capacitor disposed in ahousing of the potted DC link capacitor; and a multi-port powerconverter may include a housing including a plurality of portsstructured to electrically interface to a plurality of loads, theplurality of loads having distinct electrical characteristics; aplurality of solid state components configured to provide selectedelectrical power outputs and to accept selected electrical power inputs;and a plurality of solid state switches configured to provide selectedconnectivity between the plurality of solid state components and theplurality of ports. In embodiments, the plurality of distinct electricalcharacteristics may be selected from the electrical characteristicsconsisting of: a DC voltage, an AC voltage or voltage equivalent, a loadpower rating, a regenerative power rating, a current rating, a currentdirectionality, a response time characteristic, a frequencycharacteristic, and a phase characteristic. The inverter assembly mayfurther include a first welded connection between the potted DC linkcapacitor and each of the IGBTs, and a second welded connection betweeneach of the IGBTs and an AC motor connector of the inverter assembly.

In an aspect, a mobile application may include a motive power circuit,the motive power circuit including a power storage device and anelectrical load, wherein the power storage device and the electricalload may be selectively electrically coupled through a power bus; apower distribution unit (PDU) electrically interposed between the powerstorage device and the electrical load, wherein the PDU includes abreaker/relay positioned on one of a high side and a low side of thepower storage device; wherein the breaker/relay includes: a plurality offixed contacts electrically coupled to the power bus; a plurality ofmoveable contacts corresponding to the plurality of fixed contacts,wherein the plurality of moveable contacts may be selectivelyelectrically coupled to the plurality of fixed contacts, and wherein themoveable contacts allow power flow through the power bus whenelectrically coupled to the fixed contacts, and prevent power flowthrough the power bus when not electrically coupled to the fixedcontacts; an armature operationally coupled to at least one of themoveable contacts, such that the armature in a first position preventselectrical coupling between the at least one of the moveable contactsand the corresponding one of the fixed contacts, and the armature in asecond position allows electrical coupling between the at least one ofthe moveable contacts and the corresponding one of the fixed contacts; afirst biasing member biasing the armature into one of the first positionor the second position; and an arc suppression assembly structured toguide and disperse an opening arc between each of the plurality ofmoveable contacts and the corresponding fixed contacts; and a multi-portpower converter may include a housing including a plurality of portsstructured to electrically interface to a plurality of loads, theplurality of loads having distinct electrical characteristics; aplurality of solid state components configured to provide selectedelectrical power outputs and to accept selected electrical power inputs;and a plurality of solid state switches configured to provide selectedconnectivity between the plurality of solid state components and theplurality of ports. In embodiments, the plurality of distinct electricalcharacteristics may be selected from the electrical characteristicsconsisting of: a DC voltage, an AC voltage or voltage equivalent, a loadpower rating, a regenerative power rating, a current rating, a currentdirectionality, a response time characteristic, a frequencycharacteristic, and a phase characteristic. The plurality of moveablecontacts may be linked as a dual pole single throw contactingarrangement.

In an aspect, a multi-port power converter may include a housingincluding a plurality of ports structured to electrically interface to aplurality of loads, the plurality of loads having distinct electricalcharacteristics; a plurality of solid state components configured toprovide selected electrical power outputs and to accept selectedelectrical power inputs; a plurality of solid state switches configuredto provide selected connectivity between the plurality of solid statecomponents and the plurality of ports; and a controller may include acomponent bank configuration circuit structured to interpret a portelectrical interface description, the port electrical interfacedescription including a description of electrical characteristics forone of the plurality of ports; and a component bank implementationcircuit structured to provide solid switch states in response to theport electrical interface description, and wherein the plurality ofsolid state switches may be responsive to the solid switch states. Inembodiments, the plurality of distinct electrical characteristics may beselected from the electrical characteristics consisting of: a DCvoltage, an AC voltage or voltage equivalent, a load power rating, aregenerative power rating, a current rating, a current directionality, aresponse time characteristic, a frequency characteristic, and a phasecharacteristic. The controller may further include a load/source drivedescription circuit structured to interpret a source/load drivecharacteristic, wherein the source/load drive characteristic includes atleast one electrical characteristic requirement of a load; and aload/source drive implementation circuit structured to provide acomponent driver configuration in response to the source/load drivecharacteristic.

In an aspect, a multi-port power converter may include a housingincluding a plurality of ports structured to electrically interface to aplurality of loads, the plurality of loads having distinct electricalcharacteristics; a plurality of solid state components configured toprovide selected electrical power outputs and to accept selectedelectrical power inputs; and a plurality of solid state switchesconfigured to provide selected connectivity between the plurality ofsolid state components and the plurality of ports; and a breaker/relaymay include a fixed contact electrically coupled to a motive powercircuit for a mobile application; a moveable contact selectivelyelectrically coupled to the fixed contact, wherein the moveable contactin a first position allows power to flow through the motive powercircuit, and the moveable contact in a second position does not allowpower to flow through the motive power circuit; and a physical openingresponse portion responsive to a current value in the motive powercircuit, wherein the physical opening response portion may be configuredto move the moveable contact to the second position in response to thecurrent value exceeding a threshold current value. In embodiments, theplurality of distinct electrical characteristics may be selected fromthe electrical characteristics consisting of: a DC voltage, an ACvoltage or voltage equivalent, a load power rating, a regenerative powerrating, a current rating, a current directionality, a response timecharacteristic, a frequency characteristic, and a phase characteristic.The fixed contact may include a first fixed contact, the breaker/relayfurther including a second fixed contact, wherein the moveable contactincludes a first moveable contact corresponding to the first fixedcontact, the breaker/relay further including a second moveable contactcorresponding to the second fixed contact, and a bus bar electricallycoupling the first moveable contact to the second moveable contact.

In an aspect, a mobile application may include a motive power circuit,the motive power circuit including a power storage device and anelectrical load, wherein the power storage device and the electricalload may be selectively electrically coupled through a power bus; apower distribution unit (PDU) electrically interposed between the powerstorage device and the electrical load, wherein the PDU includes abreaker/relay positioned on one of a high side and a low side of thepower storage device; wherein the breaker/relay includes: a plurality offixed contacts electrically coupled to the power bus; a plurality ofmoveable contacts corresponding to the plurality of fixed contacts,wherein the plurality of moveable contacts may be selectivelyelectrically coupled to the plurality of fixed contacts, and wherein themoveable contacts allow power flow through the power bus whenelectrically coupled to the fixed contacts, and prevent power flowthrough the power bus when not electrically coupled to the fixedcontacts; an armature operationally coupled to at least one of themoveable contacts, such that the armature in a first position preventselectrical coupling between the at least one of the moveable contactsand the corresponding one of the fixed contacts, and the armature in asecond position allows electrical coupling between the at least one ofthe moveable contacts and the corresponding one of the fixed contacts; afirst biasing member biasing the armature into one of the first positionor the second position; and an arc suppression assembly structured toguide and disperse an opening arc between each of the plurality ofmoveable contacts and the corresponding fixed contacts; and a multi-portpower converter may include a housing including a plurality of portsstructured to electrically interface to a plurality of loads, theplurality of loads having distinct electrical characteristics; aplurality of solid state components configured to provide selectedelectrical power outputs and to accept selected electrical power inputs;and a plurality of solid state switches configured to provide selectedconnectivity between the plurality of solid state components and theplurality of ports. In embodiments, the plurality of distinct electricalcharacteristics may be selected from the electrical characteristicsconsisting of: a DC voltage, an AC voltage or voltage equivalent, a loadpower rating, a regenerative power rating, a current rating, a currentdirectionality, a response time characteristic, a frequencycharacteristic, and a phase characteristic. The plurality of moveablecontacts may be linked as a dual pole single throw contactingarrangement.

In an aspect, a mobile application may include a motive power circuit,the motive power circuit including a power storage device and anelectrical load, wherein the power storage device and the electricalload may be selectively electrically coupled through a power bus; apower distribution unit (PDU) electrically interposed between the powerstorage device and the electrical load, wherein the PDU includes abreaker/relay positioned on one of a high side and a low side of thepower storage device; wherein the breaker/relay includes: a plurality offixed contacts electrically coupled to the power bus; a plurality ofmoveable contacts corresponding to the plurality of fixed contacts,wherein the plurality of moveable contacts may be selectivelyelectrically coupled to the plurality of fixed contacts, and wherein themoveable contacts allow power flow through the power bus whenelectrically coupled to the fixed contacts, and prevent power flowthrough the power bus when not electrically coupled to the fixedcontacts; an armature operationally coupled to at least one of themoveable contacts, such that the armature in a first position preventselectrical coupling between the at least one of the moveable contactsand the corresponding one of the fixed contacts, and the armature in asecond position allows electrical coupling between the at least one ofthe moveable contacts and the corresponding one of the fixed contacts; afirst biasing member biasing the armature into one of the first positionor the second position; and an arc suppression assembly structured toguide and disperse an opening arc between each of the plurality ofmoveable contacts and the corresponding fixed contacts; and a powerconverter having a plurality of ports, wherein the power converterdetermines an electrical interface description for at least one powersource of an electric mobile application and at least one electricalload of the electric mobile application and provides solid switch statesin response to the electrical interface description, thereby configuringat least one of an AC inverter or a DC/DC converter to provide or acceptpower to the at least one of the plurality of ports according to theport electrical interface description, and installing the powerconverter into the electric mobile application. In embodiments, themobile application may further include determining which ports of thepower converter may be to be coupled to the at least one power sourceand the at least one electrical load, and wherein providing the solidswitch states includes configuring electrical characteristics of thedetermined ports according to the port electrical interface description.The plurality of moveable contacts may be linked as a dual pole singlethrow contacting arrangement.

In an aspect, a system may include a housing; a breaker/relay devicepositioned in the housing, wherein the breaker/relay device may beconfigured to interrupt a motive power circuit for an electrical vehiclesystem, where the housing may be disposed on the electrical vehiclesystem; wherein the breaker/relay device includes a physical openingresponse portion responsive to a first current value in the motive powercircuit, and a controlled opening response portion responsive to asecond current value in the motive power circuit; a precharge circuitelectrically coupled in parallel to the breaker/relay device; and apower converter having a plurality of ports, wherein the power converterdetermines an electrical interface description for at least one powersource of an electric mobile application and at least one electricalload of the electric mobile application and provides solid switch statesin response to the electrical interface description, thereby configuringat least one of an AC inverter or a DC/DC converter to provide or acceptpower to the at least one of the plurality of ports according to theport electrical interface description, and installing the powerconverter into the electric mobile application. In embodiments, thesystem may further include determining which ports of the powerconverter may be to be coupled to the at least one power source and theat least one electrical load, and wherein providing the solid switchstates includes configuring electrical characteristics of the determinedports according to the port electrical interface description. The firstcurrent value may be greater than the second current value.

In an aspect, an integrated inverter assembly may include a main coverand an opposing back cover; a coolant channel disposed between a coolantchannel cover and a coolant channel separating body; wherein powerelectronics of the inverter assembly may be thermally coupled to thecoolant channel; wherein at least one of a coolant inlet or a coolantoutlet of the coolant channel includes a quick connector without alocking element; and a power converter have a plurality of ports mayinclude a plurality of solid state components configured to provideselected electrical power outputs and to accept selected electricalpower inputs; a plurality of solid state switches electricallyinterposed between the plurality of ports and the plurality of solidstate components, wherein the plurality of solid state switches may beconfigured to selectively couple sets of the plurality of solid statecomponents to the plurality of ports; and a controller may include acomponent bank configuration circuit structured to interpret a portelectrical interface description, the port electrical interfacedescription including a description of electrical characteristics forone of the plurality of ports; and a component bank implementationcircuit structured to provide solid switch states in response to theport electrical interface description, and wherein the plurality ofsolid state switches may be responsive to the solid switch states. Inembodiments, the controller may further include: a load/source drivedescription circuit structured to interpret a source/load drivecharacteristic, wherein the source/load drive characteristic includes atleast one electrical characteristic requirement of a load; and aload/source drive implementation circuit structured to provide acomponent driver configuration in response to the source/load drivecharacteristic. The quick connector may further include a fir tree hosecoupling disposed on an outer housing wall of the quick connector.

In an aspect, a power converter with a plurality of ports may include aplurality of solid state components configured to provide selectedelectrical power outputs and to accept selected electrical power inputs;a plurality of solid state switches electrically interposed between theplurality of ports and the plurality of solid state components, whereinthe plurality of solid state switches may be configured to selectivelycouple sets of the plurality of solid state components to the pluralityof ports; and a controller may include a component bank configurationcircuit structured to interpret a port electrical interface description,the port electrical interface description including a description ofelectrical characteristics for one of the plurality of ports; and acomponent bank implementation circuit structured to provide solid switchstates in response to the port electrical interface description, andwherein the plurality of solid state switches may be responsive to thesolid switch states; and a breaker/relay may include a fixed contactelectrically coupled to a motive power circuit for a mobile application;a moveable contact selectively electrically coupled to the fixedcontact, wherein the moveable contact in a first position allows powerto flow through the motive power circuit, and the moveable contact in asecond position does not allow power to flow through the motive powercircuit; and a physical opening response portion responsive to a currentvalue in the motive power circuit, wherein the physical opening responseportion may be configured to move the moveable contact to the secondposition in response to the current value exceeding a threshold currentvalue. In embodiments, the controller may further include: a load/sourcedrive description circuit structured to interpret a source/load drivecharacteristic, wherein the source/load drive characteristic includes atleast one electrical characteristic requirement of a load; and aload/source drive implementation circuit structured to provide acomponent driver configuration in response to the source/load drivecharacteristic. The fixed contact may include a first fixed contact, thebreaker/relay further including a second fixed contact, wherein themoveable contact includes a first moveable contact corresponding to thefirst fixed contact, the breaker/relay further including a secondmoveable contact corresponding to the second fixed contact, and a busbar electrically coupling the first moveable contact to the secondmoveable contact.

In an aspect, a mobile application may include a motive power circuit,the motive power circuit including a power storage device and anelectrical load, wherein the power storage device and the electricalload may be selectively electrically coupled through a power bus; apower distribution unit (PDU) electrically interposed between the powerstorage device and the electrical load, wherein the PDU includes abreaker/relay positioned on one of a high side and a low side of thepower storage device; wherein the breaker/relay includes: a plurality offixed contacts electrically coupled to the power bus; a plurality ofmoveable contacts corresponding to the plurality of fixed contacts,wherein the plurality of moveable contacts may be selectivelyelectrically coupled to the plurality of fixed contacts, and wherein themoveable contacts allow power flow through the power bus whenelectrically coupled to the fixed contacts, and prevent power flowthrough the power bus when not electrically coupled to the fixedcontacts; an armature operationally coupled to at least one of themoveable contacts, such that the armature in a first position preventselectrical coupling between the at least one of the moveable contactsand the corresponding one of the fixed contacts, and the armature in asecond position allows electrical coupling between the at least one ofthe moveable contacts and the corresponding one of the fixed contacts; afirst biasing member biasing the armature into one of the first positionor the second position; and an arc suppression assembly structured toguide and disperse an opening arc between each of the plurality ofmoveable contacts and the corresponding fixed contacts; and a powerconverter have a plurality of ports may include a plurality of solidstate components configured to provide selected electrical power outputsand to accept selected electrical power inputs; a plurality of solidstate switches electrically interposed between the plurality of portsand the plurality of solid state components, wherein the plurality ofsolid state switches may be configured to selectively couple sets of theplurality of solid state components to the plurality of ports; and acontroller may include a component bank configuration circuit structuredto interpret a port electrical interface description, the portelectrical interface description including a description of electricalcharacteristics for one of the plurality of ports; and a component bankimplementation circuit structured to provide solid switch states inresponse to the port electrical interface description, and wherein theplurality of solid state switches may be responsive to the solid switchstates. In embodiments, the controller may further include a load/sourcedrive description circuit structured to interpret a source/load drivecharacteristic, wherein the source/load drive characteristic includes atleast one electrical characteristic requirement of a load; and aload/source drive implementation circuit structured to provide acomponent driver configuration in response to the source/load drivecharacteristic. The plurality of moveable contacts may be linked as adual pole single throw contacting arrangement.

In an aspect, an integrated inverter assembly may include a main coverand an opposing back cover; a coolant channel disposed between a coolantchannel cover and a coolant channel separating body; wherein powerelectronics of the inverter assembly may be thermally coupled to thecoolant channel; and wherein at least one of a coolant inlet or acoolant outlet of the coolant channel includes a quick connector withouta locking element; and a power converter having a plurality of ports mayinclude a plurality of solid state components configured to provideselected electrical power outputs and to accept selected electricalpower inputs; a plurality of solid state switches electricallyinterposed between the plurality of ports and the plurality of solidstate components, wherein the plurality of solid state switches may beconfigured to selectively couple sets of the plurality of solid statecomponents to the plurality of ports; and a controller may include acomponent bank configuration circuit structured to interpret a portelectrical interface description, the port electrical interfacedescription including a description of electrical characteristics forone of the plurality of ports; and a component bank implementationcircuit structured to provide solid switch states in response to theport electrical interface description, and wherein the plurality ofsolid state switches may be responsive to the solid switch states. Inembodiments, the controller may further include a load/source drivedescription circuit structured to interpret a source/load drivecharacteristic, wherein the source/load drive characteristic includes atleast one electrical characteristic requirement of a load; and aload/source drive implementation circuit structured to provide acomponent driver configuration in response to the source/load drivecharacteristic. The quick connector may further include a fir tree hosecoupling disposed on an outer housing wall of the quick connector.

In an aspect, a system may include a vehicle having a motive electricalpower path; a power distribution unit including a current protectioncircuit disposed in the motive electrical power path, the currentprotection circuit including a thermal fuse and a contactor in a seriesarrangement with the thermal fuse; a fuse thermal model circuitstructured to determine a fuse temperature value of the thermal fuse,and to determine a fuse condition value in response to the fusetemperature value; and a power converter having a plurality of ports mayinclude a plurality of solid state components configured to provideselected electrical power outputs and to accept selected electricalpower inputs; a plurality of solid state switches electricallyinterposed between the plurality of ports and the plurality of solidstate components, wherein the plurality of solid state switches may beconfigured to selectively couple sets of the plurality of solid statecomponents to the plurality of ports; and a controller may include acomponent bank configuration circuit structured to interpret a portelectrical interface description, the port electrical interfacedescription including a description of electrical characteristics forone of the plurality of ports; and a component bank implementationcircuit structured to provide solid switch states in response to theport electrical interface description, and wherein the plurality ofsolid state switches may be responsive to the solid switch states. Inembodiments, the controller may further include a load/source drivedescription circuit structured to interpret a source/load drivecharacteristic, wherein the source/load drive characteristic includes atleast one electrical characteristic requirement of a load; and aload/source drive implementation circuit structured to provide acomponent driver configuration in response to the source/load drivecharacteristic. The system may further include a current source circuitelectrically coupled to the thermal fuse and structured to inject acurrent across the thermal fuse; a voltage determination circuitelectrically coupled to the thermal fuse and structured to determine atleast one of an injected voltage amount and a thermal fuse impedancevalue, wherein the voltage determination circuit includes a high passfilter having a cutoff frequency selected in response to a frequency ofthe injected current; and wherein the fuse thermal model circuit may bestructured to determine the fuse temperature value of the thermal fusefurther in response to the at least one of the injected voltage amountand the thermal fuse impedance value.

In an aspect, a power converter have a plurality of ports may include aplurality of solid state components configured to provide selectedelectrical power outputs and to accept selected electrical power inputs;a plurality of solid state switches electrically interposed between theplurality of ports and the plurality of solid state components, whereinthe plurality of solid state switches may be configured to selectivelycouple sets of the plurality of solid state components to the pluralityof ports; and a controller may include a component bank configurationcircuit structured to interpret a port electrical interface description,the port electrical interface description including a description ofelectrical characteristics for one of the plurality of ports; and acomponent bank implementation circuit structured to provide solid switchstates in response to the port electrical interface description, andwherein the plurality of solid state switches may be responsive to thesolid switch states; and a breaker/relay may include a plurality offixed contacts electrically coupled electric load circuits for a mobileapplication; a plurality of moveable contacts, each moveable contactselectively electrically coupled to a corresponding one of the pluralityof fixed contacts; a plurality of armatures each operationally coupledto a corresponding one of the moveable contacts, such that each armaturein a first position prevents electrical coupling between thecorresponding moveable contact and the corresponding fixed contact, andeach armature in a second position allows electrical coupling betweenthe corresponding moveable contact and the corresponding fixed contact;and a current response circuit structured to determine a current in eachof the electric load circuits, and further structured to provide anarmature command to open the corresponding one of the moveable contactsin response to the current in the corresponding electrical load circuitindicating a high current value. In embodiments, the controller mayfurther include a load/source drive description circuit structured tointerpret a source/load drive characteristic, wherein the source/loaddrive characteristic includes at least one electrical characteristicrequirement of a load; and a load/source drive implementation circuitstructured to provide a component driver configuration in response tothe source/load drive characteristic. The power converter may furtherinclude a plurality of biasing members each operationally coupled to acorresponding one of the plurality of moveable contacts, and configuredto bias the corresponding one of the plurality of armatures into one ofthe first position or the second position.

In an aspect, an integrated inverter assembly may include a main coverand an opposing back cover; a plurality of IGBTs, each of the pluralityof IGBTs configured to provide at least one phase of AC power to amotor; a potted DC link capacitor operationally disposed between theIGBTs and a DC power source, and wherein the potted DC link capacitorincludes a bus bar, a common-mode choke, and a capacitor disposed in ahousing of the potted DC link capacitor; and a power converter have aplurality of ports may include a plurality of solid state componentsconfigured to provide selected electrical power outputs and to acceptselected electrical power inputs; a plurality of solid state switcheselectrically interposed between the plurality of ports and the pluralityof solid state components, wherein the plurality of solid state switchesmay be configured to selectively couple sets of the plurality of solidstate components to the plurality of ports; and a controller may include

a component bank configuration circuit structured to interpret a portelectrical interface description, the port electrical interfacedescription including a description of electrical characteristics forone of the plurality of ports; and a component bank implementationcircuit structured to provide solid switch states in response to theport electrical interface description, and wherein the plurality ofsolid state switches may be responsive to the solid switch states. Inembodiments, the controller may further include a load/source drivedescription circuit structured to interpret a source/load drivecharacteristic, wherein the source/load drive characteristic includes atleast one electrical characteristic requirement of a load; and aload/source drive implementation circuit structured to provide acomponent driver configuration in response to the source/load drivecharacteristic. The inverter assembly may further include a first weldedconnection between the potted DC link capacitor and each of the IGBTs,and a second welded connection between each of the IGBTs and an AC motorconnector of the inverter assembly.

In an aspect, a mobile application may include a motive power circuit,the motive power circuit including a power storage device and anelectrical load, wherein the power storage device and the electricalload may be selectively electrically coupled through a power bus; apower distribution unit (PDU) electrically interposed between the powerstorage device and the electrical load, wherein the PDU includes abreaker/relay positioned on one of a high side and a low side of thepower storage device; wherein the breaker/relay includes: a plurality offixed contacts electrically coupled to the power bus; a plurality ofmoveable contacts corresponding to the plurality of fixed contacts,wherein the plurality of moveable contacts may be selectivelyelectrically coupled to the plurality of fixed contacts, and wherein themoveable contacts allow power flow through the power bus whenelectrically coupled to the fixed contacts, and prevent power flowthrough the power bus when not electrically coupled to the fixedcontacts; an armature operationally coupled to at least one of themoveable contacts, such that the armature in a first position preventselectrical coupling between the at least one of the moveable contactsand the corresponding one of the fixed contacts, and the armature in asecond position allows electrical coupling between the at least one ofthe moveable contacts and the corresponding one of the fixed contacts; afirst biasing member biasing the armature into one of the first positionor the second position; an arc suppression assembly structured to guideand disperse an opening arc between each of the plurality of moveablecontacts and the corresponding fixed contacts; and wherein the motiveelectrical power path of a vehicle may be provided through a currentprotection circuit including a thermal fuse and a contactor in a seriesarrangement with the thermal fuse, wherein the mobile application:determines a current flow through the motive electrical power path;opens the contactor in response to the current flow exceeding athreshold value; confirms that vehicle operating conditions allow for are-connection of the contactor; and commands the contactor to close inresponse to the vehicle operating conditions. In embodiments, theconfirming the vehicle operating conditions may include at least onevehicle operating condition selected from the conditions consisting of:an emergency vehicle operating condition; a user override vehicleoperating condition; a service event vehicle operating condition; and are-connection command communicated on a vehicle network. The pluralityof moveable contacts may be linked as a dual pole single throwcontacting arrangement.

In an aspect, a system may include a vehicle having a motive electricalpower path; a power distribution unit including a current protectioncircuit disposed in the motive electrical power path, the currentprotection circuit including breaker/relay, the breaker/relay including:fixed contact electrically coupled to a motive power circuit for amobile application; a moveable contact selectively electrically coupledto the fixed contact, wherein the moveable contact in a first positionallows power to flow through the motive power circuit, and the moveablecontact in a second position does not allow power to flow through themotive power circuit; and a physical opening response portion responsiveto a current value in the motive power circuit, wherein the physicalopening response portion may be configured to move the moveable contactto the second position in response to the current value exceeding athreshold current value; a current source circuit electrically coupledto the breaker/relay and structured to inject a current across the fixedcontact; a voltage determination circuit electrically coupled to thebreaker/relay and structured to determine at least one of an injectedvoltage amount and a contactor impedance value, wherein the voltagedetermination circuit includes a high pass filter having a cutofffrequency selected in response to a frequency of the injected current;and a breaker/relay may include a fixed contact electrically coupled toa motive power circuit for a mobile application; a moveable contactselectively electrically coupled to the fixed contact, wherein themoveable contact in a first position allows power to flow through themotive power circuit, and the moveable contact in a second position doesnot allow power to flow through the motive power circuit; and a physicalopening response portion responsive to a current value in the motivepower circuit, wherein the physical opening response portion may beconfigured to move the moveable contact to the second position inresponse to the current value exceeding a threshold current value. Inembodiments, the fixed contact may include a first fixed contact, thebreaker/relay further including a second fixed contact, wherein themoveable contact includes a first moveable contact corresponding to thefirst fixed contact, the breaker/relay further including a secondmoveable contact corresponding to the second fixed contact, and a busbar electrically coupling the first moveable contact to the secondmoveable contact. The voltage determination circuit may further includea bandpass filter having a bandwidth selected to bound the frequency ofthe injected current.

In an aspect, a system may include an electric mobile application havinga motor and an inverter, wherein the inverter includes a plurality ofdriving elements for the motor; a controller may include a motor controlcircuit structured to provide driver commands, and wherein the pluralityof driving elements may be responsive to the driver commands; anoperating conditions circuit structured to interpret a motor performancerequest value including at least one of a power, speed, or torquerequest for the motor; a driver efficiency circuit structured tointerpret a driver activation value for each of the plurality of drivingelements of the inverter in response to the motor performance requestvalue; wherein the motor control circuit may be further structured toprovide the driver commands to de-activate at least one of the pluralityof driving elements for the motor in response to the driver activationvalue for each of the plurality of driving elements of the inverter; anda breaker/relay may include a fixed contact electrically coupled to amotive power circuit for a mobile application; a moveable contactselectively electrically coupled to the fixed contact, wherein themoveable contact in a first position allows power to flow through themotive power circuit, and the moveable contact in a second position doesnot allow power to flow through the motive power circuit; and a physicalopening response portion responsive to a current value in the motivepower circuit, wherein the physical opening response portion may beconfigured to move the moveable contact to the second position inresponse to the current value exceeding a threshold current value. Inembodiments, the fixed contact may include a first fixed contact, thebreaker/relay further including a second fixed contact, wherein themoveable contact includes a first moveable contact corresponding to thefirst fixed contact, the breaker/relay further including a secondmoveable contact corresponding to the second fixed contact, and a busbar electrically coupling the first moveable contact to the secondmoveable contact. The motor may include a three-phase AC motor, whereinthe plurality of driving elements include six driving elements, andwherein the driver efficiency circuit provides the driver activationvalue to de-activate three of the six driving elements in response tothe motor performance request value being below a threshold value.

In an aspect, a mobile application may include a motive power circuit,the motive power circuit including a power storage device and anelectrical load, wherein the power storage device and the electricalload may be selectively electrically coupled through a power bus; apower distribution unit (PDU) electrically interposed between the powerstorage device and the electrical load, wherein the PDU includes abreaker/relay positioned on one of a high side and a low side of thepower storage device; wherein the breaker/relay includes: a plurality offixed contacts electrically coupled to the power bus; a plurality ofmoveable contacts corresponding to the plurality of fixed contacts,wherein the plurality of moveable contacts may be selectivelyelectrically coupled to the plurality of fixed contacts, and wherein themoveable contacts allow power flow through the power bus whenelectrically coupled to the fixed contacts, and prevent power flowthrough the power bus when not electrically coupled to the fixedcontacts; an armature operationally coupled to at least one of themoveable contacts, such that the armature in a first position preventselectrical coupling between the at least one of the moveable contactsand the corresponding one of the fixed contacts, and the armature in asecond position allows electrical coupling between the at least one ofthe moveable contacts and the corresponding one of the fixed contacts; afirst biasing member biasing the armature into one of the first positionor the second position; an arc suppression assembly structured to guideand disperse an opening arc between each of the plurality of moveablecontacts and the corresponding fixed contacts; and a power converterhave a plurality of ports may include a plurality of solid statecomponents configured to provide selected electrical power outputs andto accept selected electrical power inputs; a plurality of solid stateswitches electrically interposed between the plurality of ports and theplurality of solid state components, wherein the plurality of solidstate switches may be configured to selectively couple sets of theplurality of solid state components to the plurality of ports; and acontroller may include a component bank configuration circuit structuredto interpret a port electrical interface description, the portelectrical interface description including a description of electricalcharacteristics for one of the plurality of ports; and a component bankimplementation circuit structured to provide solid switch states inresponse to the port electrical interface description, and wherein theplurality of solid state switches may be responsive to the solid switchstates. In embodiments, the controller may further include a load/sourcedrive description circuit structured to interpret a source/load drivecharacteristic, wherein the source/load drive characteristic includes atleast one electrical characteristic requirement of a load; and aload/source drive implementation circuit structured to provide acomponent driver configuration in response to the source/load drivecharacteristic. The plurality of moveable contacts may be linked as adual pole single throw contacting arrangement.

In an aspect, a mobile application may include a motive power circuit,the motive power circuit including a power storage device and anelectrical load, wherein the power storage device and the electricalload may be selectively electrically coupled through a power bus; apower distribution unit (PDU) electrically interposed between the powerstorage device and the electrical load, wherein the PDU includes abreaker/relay positioned on one of a high side and a low side of thepower storage device; wherein the breaker/relay includes: a plurality offixed contacts electrically coupled to the power bus; a plurality ofmoveable contacts corresponding to the plurality of fixed contacts,wherein the plurality of moveable contacts may be selectivelyelectrically coupled to the plurality of fixed contacts, and wherein themoveable contacts allow power flow through the power bus whenelectrically coupled to the fixed contacts, and prevent power flowthrough the power bus when not electrically coupled to the fixedcontacts; an armature operationally coupled to at least one of themoveable contacts, such that the armature in a first position preventselectrical coupling between the at least one of the moveable contactsand the corresponding one of the fixed contacts, and the armature in asecond position allows electrical coupling between the at least one ofthe moveable contacts and the corresponding one of the fixed contacts; afirst biasing member biasing the armature into one of the first positionor the second position; an arc suppression assembly structured to guideand disperse an opening arc between each of the plurality of moveablecontacts and the corresponding fixed contacts; and a multi-port powerconverter may include a housing including a plurality of portsstructured to electrically interface to a plurality of loads, theplurality of loads having distinct electrical characteristics; aplurality of solid state components configured to provide selectedelectrical power outputs and to accept selected electrical power inputs;and a plurality of solid state switches configured to provide selectedconnectivity between the plurality of solid state components and theplurality of ports. In embodiments, the plurality of distinct electricalcharacteristics may be selected from the electrical characteristicsconsisting of: a DC voltage, an AC voltage or voltage equivalent, a loadpower rating, a regenerative power rating, a current rating, a currentdirectionality, a response time characteristic, a frequencycharacteristic, and a phase characteristic. The plurality of moveablecontacts may be linked as a dual pole single throw contactingarrangement.

Electrical power distribution in many applications is subject to anumber of challenges. Presently available systems for controllingelectrical power distribution, such as on/off control of power suppliesand circuit paths, circuit and device protection (e.g., from overcurrentconditions) utilize a combined contactor and fuse.

Presently known contactors suffer from a number of drawbacks, includingwear and deterioration from arcs during open and close events under highpower, and deterioration during high current operation.

Presently known fuse components also suffer from a number of drawbacks.Fuses suffer from a difficulty in providing a consistent and reliabledisconnection profile, as a fuse ultimately activates from temperaturerather than current, and the temperature history, aging profile of thefuse, wear and deterioration, as well as the dynamics of currentthroughput through the fuse can all affect the actual current where fuseactivation (e.g., breaking the circuit) occurs. Additionally, fusesexperience deterioration and premature aging at high current loads, andaccordingly designing a long-lasting and consistent fuse is difficultfor systems having a high turndown ratio in the operating current range,as well as for systems having a highly variable current load duringoperations. Additionally, fuse activation is an unrecoverable event,resulting in a period of shutdown and/or system maintenance or repairafter fuse activation before the system is operable again.

Additionally, presently known combined fuse-contactor systems sufferfrom a number of drawbacks. Because the contactor is required to remainengaged throughout the rated operation of the system, and because evenan ideal fuse should not activate during rated operation of the system,there is necessarily an operational gap between rated operation of thesystem and the current protection level of the fuse. A fuse contactordesign accordingly requires that a fuse be slightly undersized, riskingfuse activation in the upper range of otherwise normal rated operation,or the fuse must be slightly oversized, risking components in the systemto exposure to current levels above a rated current level. Additionally,a fuse may be undersized to protect for a contactor failure mode wherean arc build-up in the contactor delays the current dynamics in thecircuit, resulting in a delayed activation, or even failure to activate,of the fuse and accordingly an increased risk of damage to the contactoror components in the system. The previously described difficulties intuning the fuse activation profile leads to increased design,operational, and/or capital expense, or to reduced system capability.For example, a presently known design may be overly conservative—such asutilizing components that are able to withstand current significantlyhigher than rated current values, or a true system performancesignificantly below rated current values during at least certainoperating conditions. Additionally or alternatively, a risk of componentfailure may be accepted driving higher operational costs and/or lowersystem reliability, or fuse and/or contactor maintenance schedules maybe more frequent, increasing operational costs and reducing the uptimeof the overall system. Additionally or alternatively, additional powersources, power storage, or the like may be provided to enhance theoperating capability of the system to meet desired performancecharacteristics.

Applications that have a highly variable load, highly dynamic loadprofiles, and/or high turndown ratios within the operating current rangeexacerbate all of the challenges of combined fuse-contactor systems. Forexample, mobile applications such as vehicles or mobile equipment oftenhave highly variability and low predictability of the load profileduring operations. Certain types of systems have varying categories ofloads driving different duty cycles and load profiles—for example mobileapplications that also operate additional equipment (e.g., pumps, PTOdevices, communication equipment, etc.) either during mobile operationsor while stationary. Additionally, load profiles may vary considerablydepending upon the load direction or operation—for example it may bedesirable to charge much more quickly than discharge, for example wherecharging is associated with useful operation of the system anddischarging is associated with downtime of the system. In otherexamples, motive power loads on the system may be highly distinct fromregenerative recovery of power from a load, and/or certain energyrecovery operations may have very small currents associated therewith(e.g., solar power, waste heat recovery, etc.). Presently known systemsthat are highly variable, including in load values and load types,and/or highly dynamic, further increase the design and/or operationalexpense of the system, through conservative design, redundant and/orduplicative systems to manage variability, lowered system capability,and/or acceptance of operational risk.

Mobile applications provide further challenges for previously knowncombined fuse-contactor systems. For example, many mobile applications,such as commercial and passenger vehicles, are cost sensitive to bothinitial costs of a system, and to ongoing operating costs. Additionally,downtime for service, maintenance, or system failures has a very highcost, due to large volumes and competitive markets. Accordingly, evenmodest improvements to initial costs, operating costs, and reliabilitycan make a significant impact on the outcome of the system, or make anon-marketable system competitive. Mobile applications often have alarge differential in duty cycle even for systems that have similarpower ratings. Further, mobile applications often involve systems thatare sold or otherwise transferred, where the same system can experiencea significant change in the duty cycle and operating conditions afterthe system is in the hands of a user. Accordingly, a lack of flexibilityin design parameters at the time of initial sale can limit the availablemarkets for a system, and a lack of flexibility in design parameters inuse can result in increased failures later in the life cycle of thesystem. An example system includes a vehicle having a motive electricalpower path; a power distribution unit having a current protectioncircuit disposed in the motive electrical power path, the currentprotection circuit including: a first leg of the current protectioncircuit including a pyro-fuse; a second leg of the current protectioncircuit including a thermal fuse; and where the first leg and the secondleg are coupled in a parallel arrangement; a controller, including: acurrent detection circuit structured to determine a current flow throughthe motive electrical power path; and a pyro-fuse activation circuitstructured to provide a pyro-fuse activation command in response to thecurrent flow exceeding a threshold current flow value; and where thepyro-fuse is responsive to the pyro-fuse activation command.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes where a first resistance through the first legand a second resistance through the second leg are configured such thata resulting current through the second leg after the pyro-fuse activatesis sufficient to activate the thermal fuse. An example includes aresistor coupled in a series arrangement with the thermal fuse, suchthat a resulting current through the second leg after the pyro-fuseactivates is below a second threshold current flow value. An examplesystem includes a contactor coupled in a series arrangement with thethermal fuse, the controller further including a contactor activationcircuit structured to provide a contactor open command in response to atleast one of the pyro-fuse activation command or the current flowexceeding the threshold current flow value; and/or a resistor coupled ina series arrangement with the thermal fuse, such that a resultingcurrent through the second leg after the pyro-fuse activates is below asecond threshold current flow value. An example includes a resistorcoupled in a series arrangement with the pyro-fuse, such that aresulting current through the first leg after the thermal fuse activatesis below a second threshold current flow value; and/or a second thermalfuse coupled in a series arrangement with the pyro-fuse, such that aresulting current through the first leg after the thermal fuse activatesis sufficient to activate the second thermal fuse.

An example procedure includes an operation to determine a current flowthrough a motive electrical power path of a vehicle; an operation todirect the current flow through a current protection circuit having aparallel arrangement, with a pyro-fuse on a first leg of the currentprotection circuit and a thermal fuse on a second leg of the currentprotection circuit; and an operation to provide a pyro-fuse activationcommand in response to the current flow exceeding a threshold currentflow value.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation to configure a firstresistance through the first leg and a second resistance through thesecond leg such that a resulting current through the second leg afterthe pyro-fuse activates is sufficient to activate the thermal fuse. Anexample procedure includes an operation to configure a second resistancethrough the second leg such that a resulting current through the secondleg after the pyro-fuse activates is below a second threshold currentflow value. An example procedure includes an operation to a contactorcoupled in a series arrangement with the thermal fuse, the procedurefurther including providing a contactor open command in response to atleast one of providing the pyro-fuse activation command or the currentflow exceeding the threshold current flow value; and/or an operation toconfigure a second resistance through the second leg such that aresulting current through the second leg after the pyro-fuse activatesis below a second threshold current flow value. An example procedurefurther including a resistor coupled in a series arrangement with thepyro-fuse such that a resulting current through the first leg after thethermal fuse activates is below a second threshold current flow value;and/or further including a second thermal fuse coupled in a seriesarrangement with the pyro-fuse, such that a resulting current throughthe first leg after the thermal fuse activates is sufficient to activatethe second thermal fuse.

An example system includes a vehicle having a motive electrical powerpath; a power distribution unit having a current protection circuitdisposed in the motive electrical power path, the current protectioncircuit including: a first leg of the current protection circuitincluding a thermal fuse; a second leg of the current protection circuitincluding a contactor; and where the first leg and the second leg arecoupled in a parallel arrangement; a controller, including: a currentdetection circuit structured to determine a current flow through themotive electrical power path; and a fuse management circuit structuredto provide a contactor activation command in response to the currentflow; and where the contactor is responsive to the contactor activationcommand.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes where the contactor is open during nominaloperations of the vehicle, and where the fuse management circuit isstructured to provide the contactor activation command as a contactorclosing command in response to determining that the current flow is aabove a thermal wear current for the thermal fuse; and/or where the fusemanagement circuit is further structured to provide the contactoractivation command as the contactor closing command in response todetermining that the current flow is below a current protection valuefor the motive electrical power path. An example system includes wherethe contactor is closed during nominal operations of the vehicle, andwhere the fuse management circuit is structured to provide the contactoractivation command as a contactor opening command in response todetermining that the current flow is above a current protection valuefor the motive electrical power path. An example system includes wherethe fuse management circuit is further structured to provide thecontactor activation command in response to the current flow byperforming at least one operation selected from the operationsconsisting of: responding to a rate of change of the current flow;responding to a comparison of the current flow to a threshold value;responding to one of an integrated or accumulated value of the currentflow; and responding to one of an expected or a predicted value of anyof the foregoing.

An example procedure includes an operation to determine a current flowthrough a motive electrical power path of a vehicle; an operation todirect the current flow through a current protection circuit having aparallel arrangement, with a thermal fuse on a first leg of the currentprotection circuit and a contactor on a second leg of the currentprotection circuit; and an operation to provide a contactor activationcommand in response to the current flow.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation to close the contactorin response to the current flow. An example procedure includes anoperation to determine that the current flow is below a currentprotection value for the motive electrical power path before the closingthe contactor. An example procedure includes at least one operationselected from the operations consisting of: responding to a rate ofchange of the current flow; responding to a comparison of the currentflow to a threshold value; responding to one of an integrated oraccumulated value of the current flow; and responding to one of anexpected or a predicted value of any of the foregoing. An exampleprocedure includes an operation to open the contactor in response to thecurrent flow; an operation to determine that the current flow is above acurrent protection value for the motive electrical power path beforeopening the contactor; an operation to open the contactor includingperforming at least one operation selected from the operationsconsisting of: responding to a rate of change of the current flow;responding to a comparison of the current flow to a threshold value;responding to one of an integrated or accumulated value of the currentflow; and responding to one of an expected or a predicted value of anyof the foregoing.

An example system includes a vehicle having a motive electrical powerpath; a power distribution unit having a current protection circuitdisposed in the motive electrical power path, the current protectioncircuit including: a first leg of the current protection circuitincluding a thermal fuse; a second leg of the current protection circuitincluding a solid state switch; and where the first leg and the secondleg are coupled in a parallel arrangement; a controller, including: acurrent detection circuit structured to determine a current flow throughthe motive electrical power path; and a fuse management circuitstructured to provide a switch activation command in response to thecurrent flow; and where the solid state switch is responsive to theswitch activation command.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes a contactor coupled to the current protectioncircuit, where the contactor in the open position disconnects one of thecurrent protection circuit or the second leg of the current protectioncircuit.

An example procedure includes an operation to determine a current flowthrough a motive electrical power path of a vehicle; an operation todirect the current flow through a current protection circuit having aparallel arrangement, with a thermal fuse on a first leg of the currentprotection circuit and a solid state switch on a second leg of thecurrent protection circuit; and an operation to provide a switchactivation command in response to the current flow.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation to close the solid stateswitch in response to the current flow; and/or determine that thecurrent flow is below a current protection value for the motiveelectrical power path before the closing the solid state switch. Anexample procedure includes an operation to close the solid state switchincludes performing at least one operation selected from the operationsconsisting of: responding to a rate of change of the current flow;responding to a comparison of the current flow to a threshold value;responding to one of an integrated or accumulated value of the currentflow; and responding to one of an expected or a predicted value of anyof the foregoing. An example procedure includes an operation to open thesolid state switch in response to the current flow; and/or determinethat the current flow is above a current protection value for the motiveelectrical power path before opening the solid state switch. An exampleprocedure includes an operation to open the solid state switch includesperforming at least one operation selected from the operationsconsisting of: responding to a rate of change of the current flow;responding to a comparison of the current flow to a threshold value;responding to one of an integrated or accumulated value of the currentflow; and responding to one of an expected or a predicted value of anyof the foregoing. An example procedure includes an operation to open acontactor after the opening the solid state switch, where opening thecontactor disconnects one of the current protection circuit or thesecond leg of the current protection circuit.

An example system includes a vehicle having a motive electrical powerpath; a power distribution unit having a current protection circuitdisposed in the motive electrical power path, the current protectioncircuit including: a first leg of the current protection circuitincluding a first thermal fuse; a second leg of the current protectioncircuit including a second thermal fuse and a contactor; and where thefirst leg and the second leg are coupled in a parallel arrangement; acontroller, including: a current detection circuit structured todetermine a current flow through the motive electrical power path; and afuse management circuit structured to provide a contactor activationcommand in response to the current flow; and where the contactor isresponsive to the contactor activation command.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes where the contactor is open during nominaloperations of the vehicle, and where the fuse management circuit isstructured to provide the contactor activation command as a contactorclosing command in response to determining that the current flow is aabove a thermal wear current for the first thermal fuse; and/or wherethe fuse management circuit is further structured to provide thecontactor activation command as a contactor closing command in responseto determining that the current flow is below a current protection valuefor the motive electrical power path. An example system includes avehicle operating condition circuit structured to determine an operatingmode for the vehicle, and where the fuse management circuit is furtherstructured to provide the contactor activation command in response tothe operating mode; and/or where the fuse management circuit is furtherstructured to provide the contactor activation command as a contactorclosing command in response to the operating mode including at least oneoperating mode selected from the operating modes consisting of: acharging mode; a high performance mode; a high power request mode; anemergency operation mode; and a limp home mode. An example systemincludes where the contactor is closed during nominal operations of thevehicle, and where the fuse management circuit is structured to providethe contactor activation command as a contactor opening command inresponse to determining that the current flow is above a currentprotection value for the motive electrical power path; where thecontactor is closed during nominal operations of the vehicle, and wherethe fuse management circuit is structured to provide the contactoractivation command as a contactor opening command in response to theoperating mode; and/or where the fuse management circuit is furtherstructured to provide the contactor activation command as a contactoropening command in response to the operating mode including at least oneof an economy mode or a service mode.

An example procedure includes an operation to determine a current flowthrough a motive electrical power path of a vehicle; an operation todirect the current flow through a current protection circuit having aparallel arrangement, with a first thermal fuse on a first leg of thecurrent protection circuit and a second thermal fuse and a contactor ona second leg of the current protection circuit; and an operation toprovide a contactor activation command in response to the current flow.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation to close the contactorin response to the current flow being above a thermal wear current forthe first thermal fuse; and/or closing the contactor further in responseto the current flow being below a current protection value for themotive electrical power path. An example procedure includes an operationto determine an operating mode for the vehicle, and providing thecontactor activation command further in response to the operating mode.An example procedure includes an operation to provide the contactoractivation command as a contactor closing command in response to theoperating mode including at least one operating mode selected from theoperating modes consisting of: a charging mode; a high performance mode;a high power request mode; an emergency operation mode; and a limp homemode. An example procedure includes an operation to provide thecontactor activation command as a contactor opening command in responseto determining that the current flow is above a current protection valuefor the motive electrical power path; and/or provide the contactoractivation command as a contactor opening command in response to theoperating mode including at least one of an economy mode or a servicemode.

An example system includes a vehicle having a motive electrical powerpath; a power distribution unit having a current protection circuitdisposed in the motive electrical power path, the current protectioncircuit including: a first leg of the current protection circuitincluding a first thermal fuse and a first contactor; a second leg ofthe current protection circuit including a second thermal fuse and asecond contactor; and where the first leg and the second leg are coupledin a parallel arrangement; a controller, including: a current detectioncircuit structured to determine a current flow through the motiveelectrical power path; and a fuse management circuit structured toprovide a plurality of contactor activation commands in response to thecurrent flow; and where the first contactor and the second contactor areresponsive to the plurality of contactor activation commands, therebyproviding a selected configuration of the current protection circuit.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes where the current protection circuit furtherincludes: at least one additional leg, where each additional legincludes an additional thermal fuse and an additional contactor; andwhere each additional contactor is further responsive to the pluralityof contactor activation commands, thereby providing the selectedconfiguration of the current protection circuit. An example systemincludes a vehicle operating condition circuit structured to determinean operating mode for the vehicle, and where the fuse management circuitis further structured to provide the plurality of contactor activationcommands in response to the operating mode; and/or where the fusemanagement circuit is further structured to determine an active currentrating for the motive electrical power path in response to the operatingmode, and to provide the plurality of contactor activation commands inresponse to the active current rating. An example system includes wherethe first leg of the current protection circuit further includes anadditional first contactor in a parallel arrangement with the firstthermal fuse, where the current detection circuit is further structuredto determine a first leg current flow, where the fuse management circuitis further structured to provide the plurality of contactor activationcommands further in response to the first leg current flow, and wherethe additional first contactor is responsive to the plurality ofcontactor activation commands; where the additional first contactor isopen during nominal operations of the vehicle, and where the fusemanagement circuit is structured to provide the plurality of contactoractivation commands including an additional first contactor closingcommand in response to determining that the first leg current flow is aabove a thermal wear current for the first thermal fuse: where the fusemanagement circuit is structured to provide the additional firstcontactor closing command in response to determining at least one of:that the first leg current flow is below a first leg current protectionvalue, or that the current flow is below a motive electrical power pathcurrent protection value; and/or where the additional first contactor isclosed during nominal operations of the vehicle, and where the fusemanagement circuit is structured to provide the plurality of contactoractivation commands including an additional first contactor openingcommand in response to determining at least one of: that the first legcurrent flow is above a first leg current protection value, or that thecurrent flow is above a motive electrical power path current protectionvalue.

An example procedure includes an operation to determine a current flowthrough a motive electrical power path of a vehicle; an operation todirect the current flow through a current protection circuit having aparallel arrangement, with a first thermal fuse and a first contactor ona first leg of the current protection circuit, and a second thermal fuseand a second contactor on a second leg of the current protectioncircuit; and an operation to provide a selected configuration of thecurrent protection circuit in response to the current flow through themotive electrical power path of the vehicle, where providing theselected configuration includes providing a contactor activation commandto each of the first contactor and the second contactor.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure includes an operation further including at least oneadditional leg of the current protection circuit, each additional leg ofthe current protection circuit having an additional thermal fuse and anadditional contactor, and where the providing the selected configurationof the current protection circuit includes providing a contactoractivation command to each additional contactor. An example procedureincludes an operation to determine an operating mode for the vehicle,and providing the selected configuration further in response to theoperating mode; and/or an operation to determine an active currentrating for the motive electrical power path in response to the operatingmode, and where providing the selected configuration of the currentprotection circuit is further in response to the active current rating.An example procedure includes an operation to determine an activecurrent rating for the motive electrical power path, and where providingthe selected configuration of the current protection circuit is furtherin response to the active current rating. An example procedure includesan operation where the first leg of the current protection circuitfurther includes an additional first contactor in a parallel arrangementwith the first thermal fuse, the method further including: determining afirst leg current flow, and where providing the selected configurationfurther includes providing a contactor activation command to theadditional first contactor; an operation to close the additional firstcontactor in response to determining that the first leg current flow isa above a thermal wear current for the first thermal fuse; an operationto close the additional first contactor further in response todetermining at least one of: that the first leg current flow is below afirst leg current protection value, or that the current flow is below amotive electrical power path current protection value; and/or anoperation to open the additional first contactor in response todetermining at least one of: that the first leg current flow is above afirst leg current protection value, or that the current flow is above amotive electrical power path current protection value.

An example system includes a vehicle having a motive electrical powerpath; a power distribution unit having a current protection circuitdisposed in the motive electrical power path, the current protectioncircuit including a fuse; a controller, including: a fuse status circuitstructured to determine a fuse event value; and a fuse managementcircuit structured to provide a fuse event response based on the fuseevent value.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes a fuse life description circuit structured todetermine a fuse life remaining value, where the fuse event valueincludes a representation that the fuse life remaining value is below athreshold value, and where the fuse management circuit is furtherstructured to provide the fuse event response further based on the fuselife remaining value; where providing the fuse event response includesproviding at least one of a fault code or a notification of the fuseevent value; where providing the fuse event response includes adjustinga maximum power rating for the motive electrical power path; whereproviding the fuse event response includes adjusting a maximum powerslew rate for the motive electrical power path; and/or where providingthe fuse event response includes adjusting a configuration of thecurrent protection circuit. An example system includes where the currentprotection circuit further includes a contactor coupled in a parallelarrangement to the fuse; where the fuse management circuit is furtherstructured to provide a contactor activation command in response to thefuse event value; and where the contactor is responsive to the contactoractivation command. An example system includes where the fuse managementcircuit is further structured to provide the contactor activationcommand as a contactor closing command in response to the fuse eventvalue including one of a thermal wear event or an imminent thermal wearevent for the fuse. An example system includes where the fuse managementcircuit is further structured to adjust a current threshold value forthe contactor activation command in response to the fuse life remainingvalue; and/or where providing the fuse event response includes adjustinga cooling system interface for a cooling system at least selectivelythermally coupled to the fuse in response to the fuse life remainingvalue.

An example procedure includes an operation to determine a fuse eventvalue for a fuse disposed in a current protection circuit, the currentprotection circuit disposed in a motive electrical power path of avehicle; and an operation to provide a fuse event response based on thefuse event value.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation to determine a fuse liferemaining value, where the fuse event value includes a representationthat the fuse life remaining value is below a threshold value, andproviding the fuse event response further based on the fuse liferemaining value; an operation to provide the fuse event responseincludes providing at least one of a fault code or a notification of thefuse event value; an operation to provide the fuse event responseincludes adjusting a maximum power rating for the motive electricalpower path; an operation to provide the fuse event response includesadjusting a maximum power slew rate for the motive electrical powerpath; an operation to provide the fuse event response includes adjustinga configuration of the current protection circuit. An example procedureincludes an operation where the current protection circuit furtherincludes a contactor coupled in a parallel arrangement to the fuse;where the fuse management circuit is further structured to provide acontactor activation command in response to the fuse event value; andwhere the contactor is responsive to the contactor activation command;where the fuse management circuit is further structured to provide thecontactor activation command as a contactor closing command in responseto the fuse event value including one of a thermal wear event or animminent thermal wear event for the fuse; and/or where the fusemanagement circuit is further structured to adjust a current thresholdvalue for the contactor activation command in response to the fuse liferemaining value. An example procedure includes an operation to providethe fuse event response includes adjusting a cooling system interfacefor a cooling system at least selectively thermally coupled to the fusein response to the fuse life remaining value. An example procedureincludes an operation to provide the fuse event response includesproviding at least one of a fault code or a notification of the fuseevent value. An example procedure includes an operation to determine anaccumulated fuse event description in response to the fuse eventresponse, and storing the accumulated fuse event description. An exampleprocedure includes an operation to provide the accumulated fuse eventdescription, where providing the accumulated fuse event descriptionincludes at least one of providing at least one of a fault code or anotification of the accumulated fuse event description; and an operationto provide the accumulated fuse event description in response to atleast one of a service event or a request for the accumulated fuse eventdescription.

An example system includes a vehicle having a motive electrical powerpath and at least one auxiliary electrical power path; a powerdistribution unit having a motive current protection circuit disposed inthe motive electrical power path, the current protection circuitincluding a fuse; and an auxiliary current protection circuit disposedin each of the at least one auxiliary electrical power paths, eachauxiliary current protection circuit including an auxiliary fuse; acontroller, including: a current determination circuit structured tointerpret a motive current value corresponding to the motive electricalpower path, and an auxiliary current value corresponding to each of theat least one auxiliary electrical power paths.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes a motive current sensor electrically coupled tothe motive electrical power path, where the motive current sensor isconfigured to provide the motive current value. An example systemincludes at least one auxiliary current sensor each electrically coupledto one of the at least one auxiliary electrical power paths, eachauxiliary current sensor configured to provide the correspondingauxiliary current value. An example system includes where the controllerfurther includes a vehicle interface circuit, the vehicle interfacecircuit structured to provide the motive current value to a vehiclenetwork; where the vehicle interface circuit is further structured toprovide the auxiliary current value corresponding to each of the atleast one auxiliary electrical power paths to the vehicle network;and/or further including a battery management controller configured toreceive the motive current value from the vehicle network.

An example procedure includes an operation to provide a powerdistribution unit having a motive current protection circuit and atleast one auxiliary current protection circuit; an operation to power avehicle motive electrical power path through the motive currentprotection circuit; an operation to power at least one auxiliary loadthrough a corresponding one of the at least one auxiliary currentprotection circuit; an operation to determine a motive current valuecorresponding to the motive electrical power path; and an operation todetermine an auxiliary current value corresponding to each of the atleast one auxiliary current protection circuits.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation to provide the motivecurrent value to a vehicle network; and/or an operation to receive themotive current value with a battery management controller.

An example system includes a vehicle having a motive electrical powerpath; a power distribution unit having a current protection circuitdisposed in the motive electrical power path, the current protectioncircuit including: a thermal fuse; a contactor in a series arrangementwith the thermal fuse; and a controller, including: a current detectioncircuit structured to determine a current flow through the motiveelectrical power path; and a fuse management circuit structured toprovide a contactor activation command in response to the current flow;and where the contactor is responsive to the contactor activationcommand.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes where the thermal fuse includes a current ratingthat is higher than a current corresponding to a maximum powerthroughput of the motive electrical power path. An example systemincludes where the thermal fuse includes a current rating that is higherthan a current corresponding to a quick charging power throughput of themotive electrical power path. An example system includes where thecontactor includes a current rating that is higher than a currentcorresponding to a maximum power throughput of the motive electricalpower path. An example system includes where the contactor includes acurrent rating that is higher than a current corresponding to a quickcharging power throughput of the motive electrical power path. Anexample system includes where the fuse management circuit is furtherstructured to provide the contactor activation command as a contactoropening command in response to the current flow indicating a motiveelectrical power path protection event; and/or where the currentdetection circuit is further structured to determine the motiveelectrical power path protection event by performing at least oneoperation selected from the operations consisting of: responding to arate of change of the current flow; responding to a comparison of thecurrent flow to a threshold value; responding to one of an integrated oraccumulated value of the current flow; and responding to one of anexpected or a predicted value of any of the foregoing.

An example procedure includes an operation to power a motive electricalpower path of a vehicle through a current protection circuit including athermal fuse and a contactor in a series arrangement with the thermalfuse; an operation to determine a current flow through the motiveelectrical power path; and an operation to selectively open thecontactor in response to the current flow.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation to provide the thermalfuse having a current rating that is higher than a current correspondingto a maximum power throughput of the motive electrical power path. Anexample procedure includes an operation to provide the thermal fusehaving a current rating that is higher than a current corresponding to aquick charging power throughput of the motive electrical power path. Anexample procedure includes an operation to provide the contactor havinga current rating that is higher than a current corresponding to amaximum power throughput of the motive electrical power path. An exampleprocedure includes an operation to provide the contactor having acurrent rating that is higher than a current corresponding to a quickcharging power throughput of the motive electrical power path. Anexample procedure includes an operation to open the contactor is furtherin response to at least one of: a rate of change of the current flow; acomparison of the current flow to a threshold value; one of anintegrated or accumulated value of the current flow; and an expected orpredicted value of any of the foregoing.

An example procedure includes an operation to power a motive electricalpower path of a vehicle through a current protection circuit including athermal fuse and a contactor in a series arrangement with the thermalfuse; an operation to determine a current flow through the motiveelectrical power path; an operation to open the contactor in response tothe current flow exceeding a threshold value; an operation to confirmthat vehicle operating conditions allow for a re-connection of thecontactor; and an operation to command the contactor to close inresponse to the vehicle operating conditions.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation to confirm the vehicleoperating conditions includes at least one vehicle operating conditionselected from the conditions consisting of: an emergency vehicleoperating condition; a user override vehicle operating condition; aservice event vehicle operating condition; and a re-connection commandcommunicated on a vehicle network. An example procedure includes anoperation to monitor the motive electrical power path during thecommanding the contactor to close, and re-opening the contactor inresponse to the monitoring. An example procedure includes an operationto determine an accumulated contactor open event description in responseto the opening the contactor; an operation to prevent the commanding thecontactor to close in response to the accumulated contactor open eventdescription exceeding a threshold value; and/or an operation to adjustthe accumulated contactor open event description in response to thecurrent flow during the opening the contactor. An example procedureincludes an operation to diagnose a welded contactor in response to oneof the current flow during the opening the contactor, and a monitoringof the motive electrical power path during the commanding the contactorto close. An example procedure includes an operation to diagnose awelded contactor in response to a monitoring of at least one of acontactor actuator position, a contactor actuator response, or themotive electrical power path during the opening the contactor; and/or anoperation to prevent the commanding the contactor to close in responseto the diagnosed welded contactor.

An example apparatus includes a motive electrical power currentprotection circuit structured to: determine a current flow through amotive electrical power path of a vehicle; and open a contactor disposedin a current protection circuit including a thermal fuse and thecontactor in a series arrangement with the thermal fuse in response tothe current flow exceeding a threshold value; a vehicle re-power circuitstructured to: confirm that vehicle operating conditions allow for are-connection of the contactor; and close the contactor in response tothe vehicle operating conditions.

Certain further aspects of an example apparatus are described following,any one or more of which may be present in certain embodiments. Anexample apparatus includes where the vehicle re-power circuit is furtherstructured to confirm the vehicle operating conditions by confirming atleast one vehicle operating condition selected from the conditionsconsisting of: an emergency vehicle operating condition; a user overridevehicle operating condition; a service event vehicle operatingcondition; and a re-connection command communicated on a vehiclenetwork. An example apparatus includes where the motive electrical powercurrent protection circuit is further structured to monitor the motiveelectrical power path during the closing the contactor to close, andwhere the vehicle re-power circuit is further structured to re-open thecontactor in response to the monitoring. An example apparatus includes acontactor status circuit structured to determine an accumulatedcontactor open event description in response to the opening thecontactor; where the vehicle re-power circuit is further structured toprevent the closing the contactor in response to the accumulatedcontactor open event description exceeding a threshold value; and/orwhere the contactor status circuit is further structured to adjust theaccumulated contactor open event description in response to the currentflow during the opening the contactor. An example apparatus includes acontactor status circuit structured to diagnose a welded contactor inresponse to one of, during the commanding the contactor to close: thecurrent flow during the opening the contactor; and a monitoring of themotive electrical power path by the motive electrical power currentprotection circuit. An example apparatus includes a contactor statuscircuit structured to diagnose a welded contactor in response to amonitoring of, during the opening of the contactor, at least one of: acontactor actuator position by the vehicle re-power circuit; a contactoractuator response by the vehicle re-power circuit; and the motiveelectrical power path by the motive electrical power current protectioncircuit; and/or where the contactor status circuit is further structuredto prevent the closing the contactor in response to the diagnosed weldedcontactor.

An example system includes a vehicle having a motive electrical powerpath; a power distribution unit including: a current protection circuitdisposed in the motive electrical power path, the current protectioncircuit including a thermal fuse and a contactor in a series arrangementwith the thermal fuse; a high voltage power input coupling including afirst electrical interface for a high voltage power source; a highvoltage power output coupling including a second electrical interfacefor a motive power load; and where the current protection circuitelectrically couples the high voltage power input to the high voltagepower output, and where the current protection circuit is at leastpartially disposed in a laminated layer of the power distribution unit,the laminated layer including an electrically conductive flow pathdisposed two electrically insulating layers.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes where current protection circuit includes amotive power bus bar disposed in the laminated layer of the powerdistribution unit. An example system includes where the vehicle furtherincludes an auxiliary electrical power path; where the powerdistribution unit further includes: an auxiliary current protectioncircuit disposed in the auxiliary electrical power path, the auxiliarycurrent protection circuit including a second thermal fuse; an auxiliaryvoltage power input coupling including a first auxiliary electricalinterface for a low voltage power source; an auxiliary voltage poweroutput coupling including a second auxiliary electrical interface for aan auxiliary load; and where the auxiliary current protection circuitelectrically couples the auxiliary voltage power input to the auxiliaryvoltage power output, and where the auxiliary current protection circuitis at least partially disposed in the laminated layer of the powerdistribution unit. An example system includes where the laminated layerof the power distribution unit further includes at least one thermallyconductive flow path disposed between two thermally insulating layers;where the at least one thermally conductive flow path is configured toprovide thermal coupling between a heat sink, and a heat source, wherethe heat source includes at least one of the contactor, the thermalfuse, and the second thermal fuse; where the heat sink includes at leastone of a thermal coupling to an active cooling source and a housing ofthe power distribution unit; and/or further including a thermal conduitdisposed between the at least one thermally conductive flow path and theheat source.

An example system includes a vehicle having a motive electrical powerpath; a power distribution unit including a current protection circuitdisposed in the motive electrical power path, the current protectioncircuit including a thermal fuse and a contactor in a series arrangementwith the thermal fuse; a current source circuit electrically coupled tothe thermal fuse and structured to inject a current across the thermalfuse; and a voltage determination circuit electrically coupled to thethermal fuse and structured to determine at least one of an injectedvoltage amount and a thermal fuse impedance value.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes where the motive electrical power path includesa direct current power path; where the current source circuit includesat least one of an alternating current source and a time varying currentsource, further including a hardware filter electrically coupled to thethermal fuse, the hardware filter configured in response to an injectionfrequency of the current source circuit; where the hardware filterincludes a high pass filter having a cutoff frequency determined inresponse to the injection frequency of the current source circuit; wherethe hardware filter includes a low pass filter having a cutoff frequencydetermined in response to at least one of the injection frequency of thecurrent source circuit or a load change value of the motive electricalpower path; where the hardware filter includes a low pass filter havinga cutoff frequency determined in response to at least one of theinjection frequency of the current source circuit or a load change valueof the motive electrical power path; where the voltage determinationcircuit is further structured to determine to determine an injectedvoltage drop of the thermal fuse in response to an output of the highpass filter; where the voltage determination circuit is furtherstructured to determine the thermal fuse impedance value in response tothe injected voltage drop; and/or where the voltage determinationcircuit is further structured to determine a load voltage drop of thethermal fuse in response to an output of the low pass filter, the systemfurther including a load current circuit structured to determine a loadcurrent through the fuse in response to the thermal fuse impedancevalue, and further in response to the load voltage drop.

An example system includes a vehicle having a motive electrical powerpath; a power distribution unit including a current protection circuitdisposed in the motive electrical power path, the current protectioncircuit including a thermal fuse and a contactor in a series arrangementwith the thermal fuse; a current source circuit electrically coupled tothe thermal fuse and structured to inject a current across the thermalfuse; a voltage determination circuit electrically coupled to thethermal fuse and structured to determine at least one of an injectedvoltage amount and a thermal fuse impedance value, where the voltagedetermination circuit includes a high pass filter having a cutofffrequency selected in response to a frequency of the injected current.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes where the voltage determination circuit furtherincludes a bandpass filter having a bandwidth selected to bound thefrequency of the injected current. An example system includes where thehigh pass filter includes an analog hardware filter, and where thebandpass filter includes a digital filter. An example system includeswhere the high pass filter and the bandpass filter comprise digitalfilters; where the voltage determination circuit is further structuredto determine the thermal fuse impedance value in response to theinjected voltage drop; and/or further including a fuse characterizationcircuit structured to store one of a fuse resistance value and a fuseimpedance value, and where the fuse characterization circuit is furtherstructured to update the stored one of the fuse resistance value and thefuse impedance value in response to the thermal fuse impedance value. Anexample system includes where the fuse characterization circuit isfurther structured to update the stored one of the fuse resistance valueand the fuse impedance value by performing at least one operationselected from the operations consisting of: updating a value to thethermal fuse impedance value; filtering a value using the thermal fuseimpedance value as a filter input; rejecting the thermal fuse impedancevalue for a period of time or for a number of determinations of thethermal fuse impedance value; and updating a value by performing arolling average of a plurality of thermal impedance values over time. Anexample system includes where the power distribution unit furtherincludes a plurality of thermal fuses disposed therein, and where thecurrent source circuit is further electrically coupled to the pluralityof thermal fuses, and to sequentially inject a current across each ofthe plurality of thermal fuses; and where the voltage determinationcircuit is further electrically coupled to each of the plurality ofthermal fuses, and further structured to determine at least one of aninjected voltage amount a thermal fuse impedance value for each of theplurality of thermal fuses; where the current source circuit is furtherstructured to sequentially inject the current across each of theplurality of thermal fuses in a selected order of the fuses; where thecurrent source circuit is further structured to adjust the selectedorder in response to at least one of: a rate of change of a temperatureof each of the fuses; an importance value of each of the fuses; acriticality of each of the fuses; a power throughput of each of thefuses; and one of a fault condition or a fuse health condition of eachof the fuses; and/or where the current source circuit is furtherstructured to adjust the selected order in response to one of a plannedduty cycle and an observed duty cycle of the vehicle. An example systemincludes where the current source circuit is further structured to sweepthe injected current through a range of injection frequencies; where thecurrent source circuit is further structured to inject the currentacross the thermal fuse at a plurality of injection frequencies. Anexample system includes where the current source circuit is furtherstructured to inject the current across the thermal fuse at a pluralityof injection voltage amplitudes. An example system includes where thecurrent source circuit is further structured to inject the currentacross the thermal fuse at an injection voltage amplitude determined inresponse to a power throughput of the thermal fuse. An example systemincludes where the current source circuit is further structured toinject the current across the thermal fuse at an injection voltageamplitude determined in response to a duty cycle of the vehicle.

An example procedure includes an operation to determine null offsetvoltage for a fuse current measurement system, including an operation todetermine that no current is demanded for a fuse load for a fuseelectrically disposed between an electrical power source and anelectrical load; an operation to determine a null offset voltage inresponse to no current demanded for the fuse load; and an operation tostore the null offset voltage.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation to update a stored nulloffset voltage in response to the determined null offset voltage. Anexample procedure includes an operation to diagnose a component inresponse to the null offset voltage; and/or an operation to determinewhich one of a plurality of components is contributing to the nulloffset voltage. An example procedure includes an operation to determinethat no current is demanded for the fuse load includes at least oneoperation selected from the operations consisting of an operation todetermine that a key-off event has occurred for a vehicle including thefuse, the electrical power source, and the electrical load; an operationto determine that a key-on event has occurred for the vehicle; andoperation to determine that the vehicle is powering down; and anoperation to determine that the vehicle is in an accessory condition,where the vehicle in the accessory condition does not provide powerthrough the fuse.

An example apparatus to determine offset voltage to adjust a fusecurrent determination includes a fuse load circuit structured todetermine that no current is demanded for a fuse load, and to furtherdetermine that contactors associated with the fuse are open; an offsetvoltage determination circuit structured to determine an offset voltagecorresponding to at least one component in a fuse circuit associatedwith the fuse, in response to the determining that no current isdemanded for the fuse load; and an offset data management circuitstructured to store the offset voltage, and to communicate a currentcalculation offset voltage for use by a controller to determine currentflow through the fuse.

An example procedure includes an operation to provide digital filtersfor a fuse circuit in power distribution unit, including an operation toinject an alternating current across a fuse, the fuse electricallydisposed between an electrical power source and an electrical load; anoperation to determine the base power through a fuse by performing alow-pass filter operation on one of a measured current value and ameasured voltage value for the fuse; and an operation to determine aninjected current value by performing a high-pass filter operation on oneof the measured current value and the measured voltage value for thefuse.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation to adjust parameters ofat least one of the low-pass filter and the high-pass filter in responseto a duty cycle of one of power and current through the fuse. An exampleprocedure includes an operation to sweep the injected alternatingcurrent through a range of injection frequencies. An example procedureincludes an operation to inject the alternating current across the fuseat a plurality of injection frequencies. An example procedure includesan operation where the current source circuit is further structured toinject the current across the fuse at a plurality of injection voltageamplitudes. An example procedure includes an operation where the currentsource circuit is further structured to inject the current across thefuse at an injection voltage amplitude determined in response to a powerthroughput of the fuse.

An example procedure includes an operation to calibrate a fuseresistance determination algorithm, including: an operation to store aplurality of calibration sets corresponding to a plurality of duty cyclevalues, the duty cycles including an electrical throughput valuecorresponding to a fuse electrically disposed between an electricalpower source and an electrical load; where the calibration sets includecurrent source injection settings for a current injection deviceoperationally coupled to the fuse; an operation to determine a dutycycle of a system including the fuse, the electrical power source, andthe electrical load; an operation to determine injection settings forthe current injection device in response to the plurality of calibrationsets and the determined duty cycle; and an operation to operate thecurrent injection device in response to the determined injectionsettings.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation where the calibrationsets further comprise filter settings for at least one digital filter,where the method further includes determining the fuse resistanceutilizing the at least one digital filter.

An example procedure includes an operation to 1. A method to provideunique current waveforms to improve fuse resistance measurement for apower distribution unit, including: confirming that contactorselectrically positioned in a fuse circuit are open, where the fusecircuit includes a fuse electrically disposed between an electricalpower source and an electrical load; determining a null voltage offsetvalue for the fuse circuit; conducting a plurality of current injectionsequences across the fuse, each of the current injection sequencesincluding a selected current amplitude, current frequency, and currentwaveform value; determining a fuse resistance value in response to thecurrent injection sequences and the null voltage offset value.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation to adjust filteringcharacteristics for a digital filter in response to each of theplurality of current injection sequences, and measuring one of the fusecircuit voltage and the fuse circuit current with the digital filterduring the corresponding one of the plurality of current injectionsequences using the adjusted filtering characteristics.

An example system includes a vehicle having a motive electrical powerpath; a power distribution unit including a current protection circuitdisposed in the motive electrical power path, the current protectioncircuit including a thermal fuse and a contactor in a series arrangementwith the thermal fuse; a current source circuit electrically coupled tothe thermal fuse and structured to inject a current across the thermalfuse; a voltage determination circuit electrically coupled to thethermal fuse and structured to determine an injected voltage amount anda thermal fuse impedance value, where the voltage determination circuitis structured to perform a frequency analysis operation to determine theinjected voltage amount.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes where the voltage determination circuit isfurther structured to determine the injected voltage amount bydetermining an amplitude of a voltage across the fuse at a frequency ofinterest; and/or where the frequency of interest is determined inresponse to a frequency of the injected voltage. An example systemincludes where the current source circuit is further structured to sweepthe injected current through a range of injection frequencies. Anexample system includes where the current source circuit is furtherstructured to inject the current across the thermal fuse at a pluralityof injection frequencies. An example system includes where the currentsource circuit is further structured to inject the current across thethermal fuse at a plurality of injection voltage amplitudes. An examplesystem includes where the current source circuit is further structuredto inject the current across the thermal fuse at an injection voltageamplitude determined in response to a power throughput of the thermalfuse. An example system includes where the current source circuit isfurther structured to inject the current across the thermal fuse at aninjection voltage amplitude determined in response to a duty cycle ofthe vehicle.

An example system includes a vehicle having a motive electrical powerpath; a power distribution unit including a current protection circuitdisposed in the motive electrical power path, the current protectioncircuit including a thermal fuse and a contactor in a series arrangementwith the thermal fuse; a current source circuit electrically coupled tothe thermal fuse and structured to determine that a load powerthroughput of the motive electrical power path is low, and to inject acurrent across the thermal fuse in response to the load power throughputof the motive electrical power path being low; a voltage determinationcircuit electrically coupled to the thermal fuse and structured todetermine at least one of an injected voltage amount and a thermal fuseimpedance value, where the voltage determination circuit includes a highpass filter having a cutoff frequency selected in response to afrequency of the injected current.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes where the current source circuit is furtherstructured to determine the load power throughput of the motiveelectrical power path is low in response to the vehicle being in ashutdown state. An example system includes where the current sourcecircuit is further structured to determine the load power throughput ofthe motive electrical power path is low in response to the vehicle beingin a keyoff state. An example system includes where the current sourcecircuit is further structured to determine the load power throughput ofthe motive electrical power path is low in response to a motive torquerequest for the vehicle being zero. An example system includes where thepower distribution unit further includes a plurality of fuses, and wherethe current source circuit is further structured to inject the currentacross each of the plurality of fuses in a selected sequence; and/orwhere the current source circuit is further structured to inject thecurrent across a first one of the plurality of fuses at a first shutdownevent of the vehicle, and to inject the current across a second one ofthe plurality of fuses at a second shutdown event of the vehicle.

An example system includes a vehicle having a motive electrical powerpath; a power distribution unit including a current protection circuitdisposed in the motive electrical power path, the current protectioncircuit including a thermal fuse and a contactor in a series arrangementwith the thermal fuse; a current source circuit electrically coupled tothe thermal fuse and structured to inject a current across the thermalfuse; a voltage determination circuit electrically coupled to thethermal fuse and structured to determine at least one of an injectedvoltage amount and a thermal fuse impedance value, where the voltagedetermination circuit includes a high pass filter having a cutofffrequency selected in response to a frequency of the injected current;and a fuse status circuit structured to determine a fuse condition valuein response to the at least one of the injected voltage amount and thethermal fuse impedance value.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes where the fuse status circuit is furtherstructured to provide the fuse condition value by providing at least oneof a fault code or a notification of the fuse condition value; where thefuse status circuit is further structured to adjust a maximum powerrating for the motive electrical power path in response to the fusecondition value; where the fuse status circuit is further structured toadjust a maximum power slew rate for the motive electrical power path inresponse to the fuse condition value; where the fuse status circuit isfurther structured to adjust a configuration of the current protectioncircuit in response to the fuse condition value; where the powerdistribution unit further includes an active cooling interface, andwhere the fuse status circuit is further structured to adjust the activecooling interface in response to the fuse condition value; where thefuse status circuit is further structured to clear the at least one ofthe fault code or the notification of the fuse condition value inresponse to the fuse condition value indicating that the fuse conditionhas improved; where the fuse status circuit is further structured toclear the at least one of the fault code or the notification of the fusecondition value in response to a service event for the fuse; where thefuse status circuit is further structured to determine a fuse liferemaining value in response to the fuse condition value; where the fusestatus circuit is further structured to determine the fuse liferemaining value further in response to a duty cycle of the vehicle;and/or where the fuse status circuit is further structured to determinethe fuse life remaining value further in response to one of an adjustedmaximum power rating for the motive electrical power path or an adjustedmaximum power slew rate for the motive electrical power path.

An example system includes a vehicle having a motive electrical powerpath; a power distribution unit including a current protection circuitdisposed in the motive electrical power path, the current protectioncircuit including a thermal fuse and a contactor in a series arrangementwith the thermal fuse; a fuse thermal model circuit structured todetermine a fuse temperature value of the thermal fuse, and to determinea fuse condition value in response to the fuse temperature value.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes a current source circuit electrically coupled tothe thermal fuse and structured to inject a current across the thermalfuse; a voltage determination circuit electrically coupled to thethermal fuse and structured to determine at least one of an injectedvoltage amount and a thermal fuse impedance value, where the voltagedetermination circuit includes a high pass filter having a cutofffrequency selected in response to a frequency of the injected current;and where the fuse thermal model circuit is structured to determine thefuse temperature value of the thermal fuse further in response to the atleast one of the injected voltage amount and the thermal fuse impedancevalue. An example system includes where the fuse thermal model circuitis further structured to determine the fuse condition value by countinga number of thermal fuse temperature excursion events; and/or where thethermal fuse temperature excursion events each comprise a temperaturerise threshold value within a time threshold value. An example systemincludes where the fuse thermal model circuit is further structured todetermine the fuse condition value by integrating the fuse temperaturevalue; and/or where the fuse thermal model circuit is further structuredto determine the fuse condition value by integrating the fusetemperature value above a temperature threshold.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 shows an embodiment system schematically depicting a powerdistribution unit (PDU) operationally positioned between a power sourceand a load.

FIG. 2 depicts a more detailed embodiment system schematically depictinga PDU.

FIG. 3 depicts a non-limiting example response curve for a fuse.

FIG. 4 depicts a non-limiting example system for mobile application suchas a vehicle.

FIG. 5 depicts a non-limiting example system including a PDU.

FIG. 6 depicts an embodiment apparatus including all or portions of aPDU.

FIG. 7 shows a non-limiting example of interactions between a main fuseand laminated layers.

FIG. 8 shows closer detail of a non-limiting example of interactionsbetween a main fuse and laminated layers.

FIG. 9 depicts an embodiment detailed view of a side section of thelaminated layers.

FIG. 10 shows a top view of a non-limiting example apparatus.

FIG. 11 shows an alternate side view of a non-limiting exampleapparatus.

FIG. 12 depicts an embodiment configuration showing a main fuse coupledto laminated layers on a bottom side of the main fuse.

FIG. 13 depicts an embodiment configuration showing a main fuse coupledto laminated layers on a bottom side of the main fuse with thermal fins.

FIG. 14 depicts an embodiment configuration showing a main fuse coupledto laminated layers on a bottom side of the main fuse with features forenhanced heat flow.

FIG. 15 depicts an alternate embodiment configuration showing a mainfuse coupled to laminated layers on a bottom side of the main fuse withfeatures for heat flow.

FIG. 16 depicts an alternate embodiment configuration showing a mainfuse coupled to laminated layers on a bottom side of the main fuse withfeatures for heat flow.

FIG. 17 depicts an alternate embodiment configuration showing a mainfuse coupled to laminated layers on a bottom side of the main fuse withfeatures for heat flow.

FIG. 18 shows a non-limiting example system including a PDU positionedwithin a battery pack housing or enclosure.

FIG. 19 shows a non-limiting example system including a PDU in a coolantloop for a heat transfer system.

FIG. 20 shows a non-limiting example apparatus for providing additionalprotection against fuse nuisance faults and system failures.

FIG. 21 depicts an embodiment illustrative data for implementing asystem response value.

FIG. 22 depicts a non-limiting example apparatus to measure currentthrough a fuse utilizing active current injection.

FIG. 23 depicts a non-limiting example apparatus to determine a nulloffset voltage and/or diagnose a system component.

FIG. 24 depicts a non-limiting example apparatus to provide for digitalfiltering of a current measurement through a fuse circuit.

FIG. 25 depicts a non-limiting example fuse circuit that may be presenton a PDU.

FIG. 26 depicts an embodiment of a fuse circuit with a contactor.

FIG. 27 depicts an embodiment fuse circuit including a plurality offuses.

FIG. 28 depicts a fuse circuit with fuses in parallel with a contactor.

FIG. 29 depicts illustrative data showing a fuse response to a drivecycle for a vehicle.

FIG. 30 depicts a non-limiting example system including a power sourceand s load with a fuse electrically disposed between the load and thesource.

FIG. 31 depicts a non-limiting example apparatus to determine an offsetvoltage to adjust a fuse current determination.

FIG. 32 depicts a non-limiting example apparatus is depicted to provideunique current waveforms to improve fuse resistance measurement for aPDU.

FIG. 33 depicts a non-limiting example procedure to provide uniquecurrent waveforms to improve fuse resistance measurement for a PDU.

FIG. 34 depicts a non-limiting example procedure to conduct a number ofinjection sequences.

FIG. 35 depicts an illustrative injection characteristic for an exampletest.

FIG. 36 depicts a schematic diagram of a vehicle having a PDU.

FIG. 37 depicts a schematic flow diagram of a procedure to utilize aparallel thermal fuse and pyro-fuse.

FIG. 38 depicts a schematic diagram of a vehicle having a PDU.

FIG. 39 depicts a schematic flow diagram of a procedure to operate athermal fuse bypass.

FIG. 40 depicts a schematic diagram of a vehicle having a PDU.

FIG. 41 depicts a schematic flow diagram of a procedure to operate athermal fuse bypass.

FIG. 42 depicts a schematic diagram of a vehicle having a PDU.

FIG. 43 depicts a schematic flow diagram of a procedure to operateparallel thermal fuses.

FIG. 44 depicts a schematic diagram of a vehicle having a PDU.

FIG. 45 depicts a schematic flow diagram of a procedure to selectivelyconfigure a current protection circuit.

FIG. 46 depicts a schematic diagram of a vehicle having a PDU.

FIG. 47 depicts a schematic flow diagram of a procedure to determine afuse event value, and to respond thereto.

FIG. 48 depicts a schematic diagram of a vehicle having a PDU.

FIG. 49 depicts a schematic flow diagram of a procedure to determinecurrent flow through a number of fuses.

FIG. 50 depicts a schematic diagram of a vehicle having a PDU.

FIG. 51 depicts a schematic flow diagram of a procedure to operate athermal fuse in series with a contactor.

FIG. 52 depicts a schematic flow diagram of a procedure to re-connect acontactor.

FIG. 53 depicts a schematic diagram of a vehicle having a PDU.

FIG. 54 depicts a schematic diagram of a vehicle having a PDU.

FIG. 55 depicts a schematic diagram of a vehicle having a PDU.

FIG. 56 depicts a schematic flow diagram of a procedure to determine anull offset voltage.

FIG. 57 depicts a schematic diagram of an apparatus for determining anoffset voltage.

FIG. 58 depicts a schematic flow diagram of a procedure to determine aninjected current value.

FIG. 59 depicts a schematic flow diagram of a procedure to calibrate afuse resistance algorithm.

FIG. 60 depicts a schematic flow diagram of a procedure to determine afuse resistance using a unique current waveform.

FIG. 61 depicts a schematic diagram of a vehicle having a currentprotection circuit.

FIG. 62 depicts a schematic diagram of a vehicle having a currentprotection circuit.

FIG. 63 depicts a schematic diagram of a vehicle having a currentprotection circuit.

FIG. 64 depicts a schematic diagram of a vehicle having a PDU.

FIG. 65 depicts a schematic diagram of a breaker-relay and pre-chargerelay.

FIG. 66 depicts a schematic diagram of a breaker-relay and inhibit.

FIG. 67 depicts a schematic diagram of a power bus protectionconfiguration.

FIG. 68 depicts an embodiment detail of a breaker-relay component.

FIG. 69 depicts an embodiment detail of a breaker-relay component.

FIG. 69A depicts an embodiment detail of a breaker-relay component.

FIG. 70 depicts a current plot for a contactor-fuse and breaker-relay.

FIG. 71 depicts an embodiment flow diagram for current protection.

FIG. 72 depicts an embodiment flow diagram for current protection.

FIG. 73 depicts an embodiment flow diagram for current protection.

FIG. 74 depicts an embodiment flow diagram for current protection.

FIG. 75 depicts a schematic diagram of a power protection configurationbetween a battery and an inverter.

FIG. 76 depicts a schematic diagram of a power protection configurationbetween a battery and an inverter.

FIG. 77 depicts a schematic diagram of a power protection configurationbetween a battery and loads.

FIG. 78 depicts a schematic diagram of a power protection configuration.

FIG. 79 depicts a schematic diagram of a power protection configurationbetween a battery and loads.

FIG. 80 depicts a schematic diagram of a power protection configurationbetween a battery and loads.

FIG. 81 depicts a schematic diagram of a power protection configurationbetween a battery and loads with current path depiction.

FIG. 82 depicts a schematic diagram of a power protection configurationbetween a battery and loads with current path depiction.

FIG. 83 depicts a schematic diagram of a power protection configurationbetween a battery and loads with current path depiction.

FIG. 84 depicts a schematic diagram of a power protection configurationbetween a battery and loads with current path depiction.

FIG. 85 depicts an embodiment detail of a breaker-relay component.

FIG. 86 depicts a schematic diagram of a power bus protectionconfiguration.

FIG. 87 depicts an embodiment detail of a contact in a breaker-relaycomponent.

FIG. 88 depicts an embodiment detail of a breaker-relay component.

FIG. 89 depicts a schematic diagram of a power protection configurationwith controller.

FIG. 90 depicts a schematic diagram of an adaptive system using amulti-port power converter.

FIG. 91 depicts a schematic diagram of a controller.

FIG. 92 depicts a schematic diagram of a controller with multi-portpower converter.

FIG. 93 depicts an embodiment functional diagram of a breaker-relay.

FIG. 94 depicts an embodiment schematic diagram of a breaker-relay.

FIG. 95 depicts an embodiment schematic diagram of a breaker-relayconfiguration showing certain voltage, amperage, and time-based values.

FIG. 96 depicts an embodiment schematic diagram of breaker-relayoperations.

FIG. 97 depicts an embodiment breaker-relay device with pre-chargecircuit.

FIG. 98 depicts an embodiment breaker-relay device with pre-chargecircuit.

FIG. 99 depicts an embodiment breaker-relay device with pre-chargecircuit.

FIG. 100 depicts an embodiment breaker-relay device with pre-chargecircuit.

FIG. 101 depicts an embodiment schematic diagram of a single-polebreaker/relay device.

FIG. 102 depicts detail of an embodiment dual-pole breaker/relay device.

FIG. 103 depicts detail of an embodiment dual-pole breaker/relay device.

FIG. 104 depicts detail of an embodiment dual-pole breaker/relay device.

FIG. 105 depicts detail of an embodiment dual-pole breaker/relay devicedepicting current connection components.

FIG. 106 depicts a schematic diagram of a breaker/relay device.

FIG. 107 depicts a schematic diagram of a multi-port converter withsolid state switch.

FIG. 108 depicts a schematic diagram of a multi-port converter.

FIGS. 109A and 109B depict an integrated inverter assembly.

FIG. 110 depicts an integrated inverter assembly with a batteryconnector and vehicle connector.

FIG. 111 depicts a view of an integrated inverter assembly.

FIG. 112 depicts a view of an integrated inverter assembly.

FIG. 113 depicts a view of an integrated inverter assembly with coolantchannel.

FIG. 114 depicts a view of an integrated inverter assembly with coolantchannel.

FIG. 115 depicts a view of an integrated inverter assembly with coolantchannels.

FIG. 116 depicts a view of an integrated inverter assembly with coolantchannels.

FIG. 117 depicts a view of an integrated inverter assembly withinsulated-gate bipolar transistors (IGBTs).

FIG. 118A depicts a front view of an integrated inverter assembly.

FIG. 118B depicts a side view of an integrated inverter assembly.

FIG. 119 depicts a view of an integrated inverter assembly with aperspective view depicting the gate driver PCB and the DC linkcapacitor.

FIG. 120 depicts a view of an integrated inverter assembly with AC busbars and motor temperature/position sensor.

FIG. 121 depicts a view of an integrated inverter assembly withcure-in-place gasket.

FIG. 122 depicts a view of an integrated inverter assembly with close-upof one corner of the main cover.

FIG. 123 depicts a view of an integrated inverter assembly with exampleinstallation for the IGBTs.

FIGS. 124-127 depict views of an example embodiment of a main coverportion of an integrated inverter assembly.

FIG. 128 depicts an example embodiment of an upper and lower coolingchannel.

FIG. 129 depicts an example embodiment of a coupling mechanism.

FIG. 130 depicts an example embodiment of a coupling mechanism.

FIG. 131 depicts a view of an integrated inverter assembly showing acoolant channel cover.

FIG. 132 depicts a DC Link Capacitor in the prior art.

FIG. 133 depicts an embodiment DC Link Capacitor.

FIG. 134 depicts an embodiment potted DC Link Capacitor.

FIG. 135 depicts a view of an integrated inverter assembly with AC busbars and motor temperature/position sensor.

FIG. 136 depicts a quick connector in the prior art.

FIG. 137 depicts a quick connector in the prior art.

FIG. 138 depicts an embodiment fluid connector.

FIG. 139 depicts an embodiment fluid connector.

FIG. 140 depicts a schematic diagram of a controller.

FIG. 141 depicts a schematic flow diagram of a procedure to open amotive power circuit.

FIG. 142 depicts a schematic flow diagram of a procedure to open amotive power circuit.

FIG. 143 depicts a schematic diagram of a controller.

FIG. 144 depicts a schematic flow diagram of a procedure to open amotive power circuit.

FIG. 145 depicts a schematic flow diagram of a procedure to open amotive power circuit.

FIG. 146 depicts an embodiment of a system having a breaker/relay.

FIG. 147 depicts an embodiment of a system having a breaker/relay.

FIG. 148 depicts an embodiment of a system having a breaker/relay.

FIG. 149 depicts an embodiment of a system having a breaker/relay.

FIG. 150 depicts a schematic diagram of a controller.

FIG. 151 depicts a schematic diagram of a controller.

FIG. 152 depicts a schematic flow diagram of a procedure to configure apower converter.

FIG. 153 depicts a schematic flow diagram of a procedure to integrate apower converter.

FIG. 154 depicts a schematic flow diagram of a procedure to adjustoperations of a motor.

FIG. 155 depicts a schematic flow diagram of a procedure to adjustoperations of a motor.

FIG. 156 depicts a schematic diagram of a controller.

FIG. 157 depicts a schematic diagram of a controller.

FIG. 158 depicts a schematic flow diagram of a procedure to adjustoperations of an inverter.

FIG. 159 depicts an embodiment of a system having multiple motors.

FIG. 160 depicts a schematic diagram of a controller.

FIG. 161 depicts a schematic flow diagram of a procedure to operatemultiple motors.

DETAILED DESCRIPTION

Referencing FIG. 1, an example system 100 is schematically depictedincluding a power distribution unit (PDU) 102 operationally positionedbetween a power source 104 and a load 106. The power source 104 may beany type—including at least a battery, generator, and/or capacitor. Thepower source 104 may include multiple sources or lines of power, whichmay be distributed according to the type of power (e.g., a battery inputseparated from a generator input) and/or may be distributed according tothe devices powered (e.g., auxiliary and/or accessory power separatedfrom main load power such as motive force power, and/or divisions withinthe accessories, divisions within the motive force power, etc.). Theload 106 may be any type, including one or more motive force loads(e.g., to individual drive wheel motors, to a global motive drive motor,etc.), one or more accessories (e.g., on-vehicle accessories such assteering, fan, lights, cab power, etc.). In certain embodiments, the PDU102 provides for ease of integration of the electrical system of theapplication including the system 100, such as by utilizing uniform inputand output access, grouping all power distribution into a single box,single area, and/or to a single logically integrated group ofcomponents. In certain embodiments, the PDU 102 provides for protectionof the electrical system, including fusing and/or connection ordisconnection (manual and/or automated) of the electrical system orindividual aspects of the electrical system. In certain embodiments, oneor more power sources 104 may be high voltage (e.g., motive powersources, which may be 96V, 230V-360V, 240V, 480V, or any other value) orlow voltage (e.g., 12V, 24V, 42V, or any other value). In certainembodiments, one or more power sources 104 may be a direct current (DC)power source or an alternating current (AC) power source, includingmulti-phase (e.g., three phase) AC power. In certain embodiments, thePDU 102 is a pass-through device, providing power to the load 106approximately as configured by the power source 104—for example only asaffected by sensing and other operations from the PDU 102 that are notprovided for power configuration. In certain embodiments, the PDU 102may include power electronics, for example rectifying, adjustingvoltage, cleaning up noisy electrical power, etc. to provide selectedelectrical power characteristics to the load 106.

Referencing FIG. 2, a more detailed view of an example PDU 102 isschematically depicted. The example PDU 102 includes a main power source202 (e.g., high voltage, main load power, motive power, etc.) which maybe provided by one or more power sources 104, and an auxiliary powersource 204 (e.g., auxiliary, accessory, low voltage, etc.) which may beprovided by one or more power sources 104. The example PDU 102 depicts asingle main power source 202 and a single auxiliary power source 204,but a given application may include one or more main power sources 202,and may include separated auxiliary power sources 204 and/or omitauxiliary power sources 204.

The example PDU 102 further includes a coolant inlet 206 and a coolantoutlet 204. The provision of coolant to the PDU 102 is optional and maynot be included in certain embodiments. The coolant may be of any typeaccording to availability in the application, including for example anon-vehicle coolant available (e.g., engine coolant, transmissioncoolant, a coolant stream associated with an auxiliary device or otherpower components such as a power source 104, etc.) and/or may be acoolant dedicated to the PDU 102. Where present, the amount of coolingprovided by the coolant may be variable—for example by changing anamount of coolant flowing through a coolant loop through the PDU102—such as by operating hardware (e.g. a valve or restriction) withinthe PDU 102, providing a request for a coolant flow rate to anotherdevice in the system, etc.

The example PDU 102 further includes a main power outlet 210 and anauxiliary power outlet 212. As described preceding, the PDU 102 mayinclude multiple main power outlets 210, and/or divided, multiple,multiplexed, and/or omitted auxiliary power outlets 212. The example PDU102 is a pass-through power device where, except for effects on thepower due to sensing and/or active diagnostics, the power outlets 210,212 have approximately the same electrical characteristics of thecorresponding power inlets 202, 204. However, the PDU 102 can includepower electronics (solid state or otherwise) to configure power in anydesired manner.

The example PDU 102 further includes a controller 214 configured tofunctionally execute certain operations of the PDU 102. The controller214 includes and/or is communicatively coupled to one or more sensorsand/or actuators in the PDU 102, for example to determine currentvalues, voltage values, and/or temperatures of any power source orinput, fuse, connector, or other device in the PDU 102. Additionally oralternatively, the controller 214 is communicatively coupled to thesystem 100 including the PDU 102, including for example a vehiclecontroller, engine controller, transmission controller, applicationcontroller, and/or network device or server (e.g., a fleet computer,cloud server, etc.). The controller 214 may be coupled to an applicationnetwork (e.g., a CAN, a datalink, a private or public network, etc.), anoutside network, and/or another device (e.g., an operator's portabledevice, an in-cab computer for a vehicle, etc.). The controller 214 isdepicted schematically as a single stand-alone device for convenience ofillustration. It will be understood that the controller 214 and/oraspects of the controller 214 may be distributed across multiplehardware devices, included within another hardware device (e.g., acontroller for the power source, load, vehicle, application, etc.),and/or configured as hardware devices, logic circuits, or the like toperform one or more operations of the controller 214. The PDU 102 isdepicted schematically as a device within a single enclosure, but may bewithin a single enclosure and/or distributed in two or more placeswithin an application. In certain embodiments, the inclusion of the PDU102 within a single enclosure provides certain advantages forintegration, reduction of footprint, and/or simplification ofinterfaces. Additionally or alternatively, inclusion of the PDU 102 inmore than one location in an application is contemplated herein, and/orthe inclusion of more than one PDU 102 within an application iscontemplated herein.

The example PDU 102 includes a main contactor 216 selectivelycontrolling the main power throughput of the PDU 102. In the example,the main contactor 216 is communicatively coupled to and controlled bythe controller 214. The main contactor 216 may additionally becontrollable manually, and/or other main contactors 216 may be in-linefor the main power that are controllable manually. An example maincontactor 216 includes a solenoid (or other coil-based) contactor, suchthat energizing the solenoid provides for either connected main power(e.g., normally open, or power is disconnected when not energized)and/or energizing the solenoid provides for disconnected main power(e.g., normally closed, or power is connected when not energized). Thecharacteristics of the system 100, including design choices aboutwhether power should be active when controller 214 power fails,servicing plans, regulations and/or policies in place, the consequencesof power loss for the system 100, the voltage typically carried on themain power source, the availability of a positive manual disconnectoption, and the like, may inform or dictate the decision of whether themain contactor 216 is normally open or normally closed. In certainembodiments, the main contactor 216 may be a solid state device such asa solid state relay. Where more than one main contactor 216 is present,the various contactors may include the same or distinct hardware (e.g.,one is a solenoid and one is a solid state relay), and/or may includethe same or distinct logic for being normally open or normally closed.The main contactor 216 may be additionally controllable by devicesoutside the PDU 102—for example a keyswitch lockout, another controllerin the system 100 having access to control the main contactor 216, etc.,and/or the controller 214 may be responsive to outside commands to openor close the main contactor 216, and/or additional contactors in-linefor the main power may be responsive to devices outside the PDU 102.

The example PDU 102 includes an auxiliary contactor 218 selectivelycontrolling the auxiliary power throughput of the PDU 102. In theexample, the auxiliary contactor 218 is communicatively coupled to andcontrolled by the controller 214. The auxiliary contactor 218 mayadditionally be controllable manually, and/or other auxiliary contactor218 may be in-line for the auxiliary power that are controllablemanually. An example auxiliary contactor 218 includes a solenoid (orother coil-based) contactor, such that energizing the solenoid providesfor either connected auxiliary power (e.g., normally open, or power isdisconnected when not energized) and/or energizing the solenoid providesfor disconnected auxiliary power (e.g., normally closed, or power isconnected when not energized). The characteristics of the system 100,including design choices about whether power should be active whencontroller 214 power fails, servicing plans, regulations and/or policiesin place, the consequences of power loss for the system 100, the voltagetypically carried on the auxiliary power source(s), the availability ofa positive manual disconnect option, and the like, may inform or dictatethe decision of whether the auxiliary contactor 218 is normally open ornormally closed. In certain embodiments, the auxiliary contactor 218 maybe a solid state device such as a solid state relay. The auxiliarycontactor 218 may be additionally controllable by devices outside thePDU 102—for example a keyswitch lockout, another controller in thesystem 100 having access to control the auxiliary contactor 218, etc.,and/or the controller 214 may be responsive to outside commands to openor close the auxiliary contactor 218, and/or additional contactorsin-line for the auxiliary power may be responsive to devices outside thePDU 102. In certain embodiments, auxiliary contactors 218 may beprovided for each auxiliary line, for subsets of the auxiliary lines(e.g., four auxiliary power inputs, with 2, 3, or 4 auxiliary contactors218), etc.

An example PDU 102 includes a current source 220, which may be analternating current source, and/or which may be provided as solid stateelectronics on the controller 214. The current source 220 is capable ofproviding a selected current injection to the main power across a mainfuse 222, for example as AC current, DC current, and/or controllablecurrent over time. For example, the PDU 102 may include sensors such asvoltage and/or current sensors on the main power, and the current source220 provides an electrical connection to a power source (which may be anexternal power source and/or sourced through the controller) in a mannerconfigured to inject the desired current to the main power. The currentsource 220 may include feedback to ensure the desired current isinjected, for example to respond to system noise, variability, andaging, and/or may apply the nominal electrical connection to injectcurrent, and the controller 214 determines sensor inputs to determinewhat current was actually injected on the main power. The example PDU102 depicts a current source 220 associated with the main fuse 222, butthe PDU 102 may further include one or more current sources 220associated with any one or more of the fuses 222, 224 in the PDU 102,including across fuses individually, in subsets, or across all of thefuses (subject to compatibility of power on the fuses—for examplesimultaneous current injection across electrically coupled fuses shouldgenerally be avoided) at once. It can be seen that the inclusion ofadditional current sources 220 provides for greater resolution ininjecting current across individual fuses and in managing variation ofthe fuses over time, which the inclusion of fewer current sources 220reduces system cost and complexity. In certain embodiments the currentsource 220 is configured to selectively inject current across each fusein the PDU 102, and/or across each fuse of interest, in a sequence orschedule, and/or as requested by a controller 214.

The example PDU 102 includes the main fuse 222 and the auxiliary fuses224. The main fuse 222 or fuses are associated with the main power, andthe auxiliary fuses 224 are associated with the auxiliary power. Incertain embodiments, the fuses are thermal fuses, such as resistivedevices that exhibit heating, and are intended to fail if a givencurrent profile is exceeded in the associated power line. ReferencingFIG. 3, a typical and non-limiting example response curve for a fuse isdepicted. The curve 302 represents an application damage curve,depicting a current-time space over which some aspect of the applicationwill be damaged if the curve is exceeded. For example, in the exampleapplication damage curve 302, if 10× rated current is exceeded for about50 milliseconds, damage to some aspect of the application will occur. Itwill be understood that an application may contain many components, andthat the components may differ in the application damage curve 302.Additionally, each fuse 222, 224 may be associated with distinctcomponents having a different damage curve than other components. Thecurve 304 represents a control space, wherein in certain embodiments,the controller 114 provides control protection to keep the system fromreaching the application damage curve 302 in the event of a fuse failureor off-nominal operation. The application damage curve 302 may be aspecified value, for example a system requirement to be met, whereexceedance of the application damage curve 302 does not meet the systemrequirement, although actual damage to components may be experienced atsome other value in the current-time space. The curve 306 represents thefuse melting line for an illustrative fuse. At the position of the fusemelting line 306, the fuse temperature exceeds the fuse designtemperature, and the fuse melts. However, the fuse continues conductingfor a period of time after melting commences, as depicted by the fuseconduction line 308 (e.g., due to conduction through the melted materialbefore the connection is broken, arcing, and the like). When thetime-current space reaches the fuse conduction line 308, the fuse is nolonger conducting on the power line, and the line is disconnected. Itwill be understood that specific system dynamics, fuse-to-fusevariability, fuse aging (e.g., induced mechanical or thermaldegradation, changes in composition or oxidation, and the like), theexact nature of the current experienced (e.g., the rise time of thecurrent), and other real-world variables will affect the exact timing ofboth fuse melting and fuse disconnection. However, even with a nominalfuse as depicted in FIG. 3, it can be seen that for very high currents,the nominal fuse conduction line 308, and even the fuse melting line306, can cross the application damage curve 302—for example becausecertain dynamics of the fuse disconnection operation are less responsive(in the time domain) or unresponsive to the current applied at very highcurrent values.

The example PDU 102 further includes a conduction layer 226 associatedwith the auxiliary power, and a conduction layer 228 associated with themain power. The conduction layers 226, 228 include the power couplingsof the power lines to the fuses. In certain embodiments, the conductionlayers 226, 228 are just wires or other conductive couplings between thefuses and the power connections to the PDU 102. Additionally oralternatively, conduction layers 226, 228 may include flat or laminatedportions, for example with stamped or formed conductive layers, toprovide power connections within the PDU 102, and/or portions of theconduction layers 226, 228 may include flat or laminated portions.Without limitation to any other disclosures provided herein, theutilization of flat or laminated portions provides for flexibility inthe manufacture of the conduction layers 226, 228, flexibility in theinstallation and/or a reduced installed footprint of the conductionlayers 226, 228, and/or provides for greater contact area between theconduction layers 226, 228 and portions of the PDU 102—for example thefuses, controller, contactors, or other devices within the PDU 102 wherethermal and/or electrical contact between the conduction layers 226, 228and the other devices are desired. The example conduction layers 226,228 are depicted in association with the fuses, but the conductionlayers 226, 228 may additionally or alternatively be associated with thecontroller 214 (e.g., power coupling, communications within or outsidethe PDU 102, coupling to actuators, coupling to sensors, and/or thermalcoupling), contactors 216, 218, and/or any other device within the PDU102.

Referencing FIG. 4, an example system 400 is a mobile application suchas a vehicle. The example system 400 includes the high voltage battery104 electrically coupled to high voltage loads 106 through the PDU 102.In the example system 400, an auxiliary prime mover, such as an internalcombustion engine 402 (with associated conversion electronics, such as agenerator, motor-generator, and/or inverter) is additionally coupled tothe PDU 102. It is understood that the high voltage battery 104 and/orthe auxiliary prime mover 402 may act as a power source or a load duringcertain operating conditions of the system 400, and additionally thehigh voltage loads 106 (e.g., electric motors or motor-generatorscoupled to the wheels) may act as a load or a source during certainoperating conditions. The description of loads 106 and sources 104herein is non-limiting, and references only nominal operation, ordinaryoperation, and/or operational conditions selected for conceptualdescription, even if the described load 106 and/or source 104 often,usually, or always operates in a mode that is not the described name.For example, the high voltage battery 104 may operate as a power sourceduring motive operations where net energy is being taken from thebattery, and/or as a load during charging operations, motive operationswhere the wheels or auxiliary prime mover are charging the battery, etc.

The example system 400 further includes a powertrain controller 404 tocontrol operations of the powertrain, which may be associated withanother component in the system 400, and/or part of another controllerin the system (e.g., a vehicle controller, battery controller, motor ormotor-generator controller, and/or engine controller). The examplesystem 400 further includes a charger 406 coupled to the high voltagebatter 404 through the PDU 102, and low voltage loads (“12V Auto Loads”in the example of FIG. 4) representing auxiliary and accessory loads inthe system 400. One of skill in the art will recognize the system 400 asincluding a serial hybrid powertrain for a vehicle—for example whereauxiliary power (e.g., the internal combustion engine) interacts onlywith the electrical system to re-charge batteries and/or provideadditional real-time electrical power during operations, but does notmechanically interact with the drive wheels. Additionally oralternatively, a system may include a parallel hybrid system, whereauxiliary power can interact mechanically with the drive wheels, and/orinteract with the electrical system (either, or both). Additionally oralternatively, a system may be a fully electric system, where auxiliarypower is not present, and/or where auxiliary power is present but doesnot interact with the high voltage/motive power system (e.g., analternative power unit to drive accessories, refrigeration, or thelike—which power may be communicated through the PDU 102 but separatedfrom the motive power electrical system). In certain embodiments, motivesystems such as vehicles experience highly transient load cycles—forexample during acceleration, deceleration, stop-and-go traffic,emergency operations, and the like—and accordingly management of powerin such system is complex, and certain devices such as fuses can bevulnerable to the highly transient load cycle. Additionally oralternatively, loss of operations for vehicles can result in costs forsystem down-time, loss or untimely delivery of cargo, and/or significantoperational risks due to failures (e.g., stranding the operator and/orvehicle, loss of operations in traffic, loss of operations on amotor-way, etc.). In certain embodiments, other systems that may behybrid electric and/or fully electric are additionally or alternativelysubject to highly variable duty cycles and/or specific vulnerabilitiesto operational interruptions, such as, without limitation, pumpingoperations, process operations for a larger process (e.g., chemical,refining, drilling, etc.), power generation operations, miningoperations, and the like. System failures for these and other operationsmay involve externalities such as losses associated with the processfailure that go beyond the down-time for the specific system, and/ordown-time for such systems can incur a significant cost.

Referencing FIG. 5, an example system is depicted including a PDU 102.The example PDU 102 has a number of auxiliary power connections (e.g.,charging, power steering, vehicle accessories, and a load return forcurrent detection, in the example), and a main motive/traction powerconnection. The example system 500 includes two high voltage contactors,one for each of the battery high side and low side, where in the exampletwo high voltage contactors are controllable by the system control boardbut may be additionally or alternatively manual (e.g., a switchaccessible by an operator). The system control board additionally cancontrol a master disconnect that can disconnect all power through thePDU 102. The system 500 further depicts a power fuse bypass 502,controllable by the system control board, that supports certainoperations of the present disclosure as described throughout. The system500 depicts a power fuse bypass 502, but may additionally oralternatively include an auxiliary bypass for one or more of theauxiliary fuses, any subset of the auxiliary fuses, and/or for all ofthe auxiliary fuses together. The example system 500 includes anoptional coolant supply and return coupling. The battery coupling in thesystem 500 depicts a 230V to 400V battery coupling, but the high voltagecoupling may be any value. The system control board is depicted ascommunicatively coupled to a 12V CAN network, although the communicativecoupling of the system control board to the surrounding application orsystem can be any network understood in the art, multiple networks(e.g., vehicle, engine, powertrain, private, public, OBD, etc.), and/ormay be or may include a wireless network connection.

Referencing FIG. 6, an illustrative apparatus 1300 is depicted, whichmay include all or portions of a PDU 102. Any descriptions referencinginteractions between the main fuse 222 and laminated layers 226/228herein additionally or alternatively contemplate interactions betweenany fuses and/or connectors in the apparatus 1300, and/or any othercomponent of a PDU 102 as described throughout the present disclosure.The example apparatus 1300 includes contactors 216/218 which may be highvoltage contactors, and/or may be associated with various ones of thefuses 222, 224 in the apparatus 1300. The apparatus 1300 includeslaminated layers 226/228, which may include conductive layers forcertain aspects of the conductive circuitry in the apparatus 1300. Thelaminated layers 226/228 may additionally or alternatively providestiffness and/or structural support for various components in theapparatus 1300. The laminated layers 226/228 may be configured tointeract with any components in a manner desired to support thefunctions of the laminated layers 226/228, including structuralfunctions, heat transfer functions, and/or electrical conductivityfunctions. The example laminated layers 226/228 interact with allcontactors and fuses in the apparatus 1300, although laminated layers226/228 can readily be configured to interact with selected ones of thecontactors and/or fuses, and/or with other components in the apparatus,for example in a manner similar to a printed circuit board (PCB) design.The example apparatus 1300 is positioned on a L-bracket, which may be afinal configuration, and/or may be a test configuration. In certainembodiments, the apparatus 1300 is enclosed in a dedicated housing,and/or enclosed in a housing of another device in a system 100—such asthe battery housing. In certain embodiments, the apparatus 1300 includesa removable housing portion (e.g., a top portion, lid, etc.) for serviceand/or maintenance access to the components of the apparatus. Theexample apparatus 1300 includes connectors 1302—for example to providepower, datalink access, connections to the power source 104, connectionsto loads 106, connections to sensors (not shown), and/or any other typeof connection to the system 100 or otherwise.

Referencing FIG. 7, an alternate view of an apparatus 1300 is depicted.The apparatus 1300 depicted in FIG. 7 shows the physical interactionbetween the main fuse 222 and the laminated layers 226/228 for anexample embodiment. Referencing FIG. 8, a closer detail view ofinteractions between the main fuse 222 and the laminated layers 226/228is depicted for an example embodiment. In the example of FIG. 8, it canbe seen that the main fuse 222 includes a relatively large thermalcontact area with the laminated layers 226/228 on a bottom side of thefuse, and a relatively small thermal contact area with the laminatedlayers 226/228 on the mounting sides (e.g., through the mountingcomponents). The thermal contact area between the main fuse 222 and thelaminated layers 226/228 is selectable, and in certain embodiments themounting side or an open side of the main fuse 222 includes a greaterthermal contact area, and/or the bottom side includes a large thermalcontact area or is not in significant thermal contact with the laminatedlayers 226/228.

Referencing FIG. 9, a detail view of a side section of the laminatedlayers 226/228 is depicted. The laminated layers 226/228 in the exampleinclude an outer structural layer 1402 and an opposing outer structurallayer (not numbered), with an interstitial space 1404 between the outerstructural layers. In certain embodiments, conductive flow paths and/orthermal flow paths are provided in the interstitial space 1404 betweenthe structural layers. It will be understood that the use of two outerstructural layers 1402 provides certain mechanical advantages, includingincreased durability to shocks and minor impacts, denting of a layer,and bending or flexing of the PDU 102. Additionally or alternatively,the use of two outer structural layers 1402 provides for improvedmechanical moments for certain types of stresses. Accordingly, incertain embodiments, the interstitial space 1404 is empty (e.g., itforms a gap), and/or negligible (e.g., the outer layers are sandwicheddirectly together at least in certain portions of the PDU 102), andnevertheless an improved design is achieved. In certain embodiments, theinterstitial space 1404 includes thermally conductive members (e.g.,high thermal conductivity paths at selected locations), electricallyconductive members (e.g., high electrical conductivity paths at selectedlocations), active and/or convective thermal paths (e.g., coolant orother convective thermal materials that flow through selected paths inthe interstitial space 1404), insulating materials (e.g., to directelectrical or heat flow, and/or to separate components or layerselectrically and/or thermally), and/or dielectric materials (e.g., toimprove electric isolation of components and/or layers).

Referencing FIG. 10, a top view of an example apparatus 1300 isdepicted. The laminated layers 226/228 are distributed throughout theapparatus 1300, providing selectable support, thermal conductivitypaths, and/or electrical conductivity paths, to any desired componentsin the apparatus. Referencing FIG. 11, a side detail view of theinteractive space 1408 between the laminated layers 226/228 and the mainfuse 222 is depicted. The interactive space includes thermallyconductive paths between mount points on the main fuse 222 and thelaminated layers 226/228. Additionally, the interstitial space 1404between the layers is present, in the example, along both the bottom andside of the main fuse 222. Accordingly, desired thermal transfer and/orelectrical communication between the main fuse 222 and the interstitiallayer 226/228 (and thereby with any other selected components in theapparatus 1300) is available as desired. In certain embodiments, greaterthermal and/or electrical coupling between the main fuse 222 and thelaminated layers 226/228 is provided—for example by running thelaminated layers 226/228 along the housing of the main fuse 222 ratherthan offset from the housing, and/or by providing a thermally conductiveconnection (e.g., thermal grease, silicone, and/or contact utilizing anyother thermally coupling material such as a metal or other conductor)between the main fuse 222 and the laminated layers 226/228.

Referencing FIG. 12, a main fuse 222 coupled to laminated layers 226/228on a bottom side of the main fuse 222 is depicted. The example of FIG.12 depicts a thermally conductive layer 1406 disposed between the mainfuse 222 and the laminated layers 226/228—for example thermal grease,silicone, a silicone pad, a mounted metal material, and/or any otherthermally conductive layer understood in the art. In the example of FIG.12, the increased effective thermal contact area provides for greaterheat transfer away from the main fuse 222 when the main fuse 222 getshotter than the laminated layer 226, 228. Additionally, the heat can bedirected away by the inclusion of a thermally conductive material withinthe interstitial space 1404 (e.g., reference FIG. 14), including forexample utilizing a conductive path the direct heat to a selectedportion of a PDU housing, to an active cooling exchange, heating fins,or the like. In the example of FIG. 12, the support layers 226/228 thatthe fuse 222 is coupled to in FIG. 12 may additionally or alternativelyinclude be only a single layer (e.g., not a laminated layer, and/orlayers 226, 228 having no interstitial space 1404), a housing of the PDU102, and/or another component in a system 100 such as a battery packhousing. In certain embodiments, the heat conductivity in FIG. 12 isenhanced by the laminated layers 226/228, for example by the inclusionof a highly conductive channel in the interstitial space 1404, which maybe improved by the structural support, routing availability, and/orenvironmental isolation provided by the laminated layers 226/228.Referencing FIG. 13, in addition to the features depicted in FIG. 12,fins 1502 for improved heat transfer and/or structural rigidity aredepicted upon the laminated layers 226/228 (which may be laminatedlayers, a single layer, a housing wall, etc.). In certain embodiments,the fins are oriented such that fluid flows past them in a direction toenhance heat transfer (e.g., oriented for improved effective flow areaand/or turbulence generation in a liquid flow, to maximize effectivearea in a gas flow, and/or to allow natural convection of fluid—such asgas rising—to cause a high effective flow area of the fins 1502). Incertain embodiments, for example where the support layers 226, 228(and/or layer 226) is a portion of a housing, battery pack housing, orother device, the fins 1502 may instead be presented into ambient air, aforced air flow region, or in a region to be in contact with anyselected fluid to facilitate heat transfer to the fluid.

Convective heat transfer, as utilized herein, includes any heat transferpath wherein convective heat transfer forms at least a portion of theoverall heat transfer mechanism. For example, where a portion of theheat transfer is conductive (e.g., through a wall, thermal grease, etc.)into a flowing fluid (where generally convective heat transferdominates), then the heat transfer mechanism is convective and/orincludes a convective portion. In certain embodiments, heat transferutilizing an active or passively flowing fluid include convective heattransfer as utilized herein. The heat transfer may be dominated byconduction under certain operating conditions, dominated by convectionunder certain operating conditions, and/or include contributing mixes ofconductive and convective heat transfer under certain operatingconditions.

Referencing FIG. 14, in addition to the features depicted in FIG. 12, afluid flow 1602 through the interstitial space 1404 is provided, whichin certain embodiments enhances the heat flow from the main fuse 222 tothe laminated layers 226/228. The fluid flow 1602 may be a coolant(e.g., a vehicle, engine, battery pack, and/or transmission coolant, orother coolant source available in the system), and/or may be a dedicatedcoolant such as a closed system for the PDU 102 and/or power source 104.In certain embodiments, the fluid flow 1602 includes a gas (e.g., air,compressed air, etc.). In certain embodiments, coolant flow may beactive (e.g., through a valve from a pressurized source, and/or pumped)or passive (e.g., configured to occur during normal operations withoutfurther control or input).

Referencing FIG. 15, a main fuse 222 is depicted having enhanced thermalconnectivity to laminated layers 226, 228 (which may be laminated, asingle layer, a housing, etc.). In the example, enhanced thermalconductivity is provided by a thermal coupling layer 1406, but mayalternatively or additionally include positioning the layers 226, 228 inproximity to the main fuse 222, and/or providing another highconductivity path (e.g., a metal, etc.) to a selected location of thelayer 226, 228 and/or the thermal coupling layer 1406. The embodiment ofFIG. 15 provides additional heat transfer capability for the main fuse222, similar to that depicted in FIG. 12, and the embodiments of FIGS.12, 13, 14, and 15 may be fully or partially combined.

Referencing FIG. 16, a high conductivity thermal path 1702 to move heatout of the laminated layers 226/228 is depicted. The high conductivitythermal path 1702 may be combined with any other embodiments describedthroughout the present disclosure to control heat flow in a desiredmanner. In certain embodiments, the high conductivity thermal path 1702is thermally coupled 1706 to another portion of the laminated layers226, 228, to a housing, to a single layer, or to any other desiredcomponent in the PDU 102 or within thermal connectivity of the PDU 102.The portion of FIG. 16 receiving the transferred heat may additionallyor alternatively be coupled to active or passive heat transfercomponents, include fins or other heat transfer enhancement aspects,and/or may be thermally coupled to a convective heat transfer componentor fluid.

Referencing FIG. 17, the fluid flow 1602 is displaced from the portionof the laminated layers 226/228 in direct thermal contact to the mainfuse 222. The example includes the fluid flow 1602 below the main fuse222, and the main fuse 222 thermally coupled to the laminated layers226/228 on the sides of the fuse, but the fluid flow 1602 may be oneither side or both sides of the main fuse 222, with the main fuse 222thermally coupled to another one of the sides and/or the bottom of themain fuse 222, and combinations of any of the foregoing. Thedescriptions of FIGS. 12 through 17 are described in the context of themain fuse 222, but the embodiments therein may apply to any one or moreselected components of the PDU 102, including without limitation anyfuse, connector, and/or controller positioned within the PDU 102.

Referencing FIG. 18, an example system includes the PDU 102 positionedwithin a battery pack housing or enclosure, where the battery cells(e.g., power source 104) are thermally coupled to a heating/coolingsystem 1802 present in the system. Additionally or alternatively, thePDU 102 may be thermally coupled to the battery cells 104, for examplewith conductive paths, at a housing interface, or the like, and/or thePDU 102 may be thermally isolated from the battery cells 104 and/or onlyin nominal thermal connectivity with the battery cells 104 (e.g., anarrangement where some heat transfer therebetween is expected, butwithout intentional design elements to increase the heat transferbetween the PDU 102 and the battery cells 104). Referencing FIG. 19, anexample system includes the PDU 102 in the coolant loop for the heattransfer system 1802, for example with thermal coupling aspects providedto transfer heat from the PDU 102 to the coolant loop and/or with thecoolant loop including a flow branch in thermal contact with the PDU102. The example in FIG. 19 depicts a series coolant arrangement betweenthe battery cells 104 and the PDU 102, but any arrangement iscontemplated herein including at least a parallel arrangement, a seriesarrangement with the PDU 102 contacted first, and/or mixed arrangements(e.g., portions of one of the battery cells 104 and the PDU 102contacted, then all or a portion of the other, etc.).

An example procedure includes an operation to provide active and/orpassive cooling to a temperature sensitive component on a PDU 102. Theexample procedure further includes cooling the temperature sensitivecomponent sufficiently to extend a life of the component to a designedservice life, to a predetermined maintenance interval, to a life and/orpredetermined maintenance interval of the PDU 102 and/or a battery pack,and/or to reduce a temperature of a fuse to avoid thermal/mechanicaldamage to the fuse, a “nuisance fault” of the fuse (e.g., a failure ofthe fuse not occurring due to a designed protective mechanism of thefuse, such as over-current operation).

In certain embodiments, fuse design imposes complications on system—forexample a fuse threshold may be desired for the fuse to engage betweenabout 135% up to 300% of the system overcurrent threshold value.However, a fuse on the smaller end of the scale may fail due to thermaland/or mechanical fatigue over the life of the system, causing a“nuisance failure” or a fuse failure that is not due to the protectivefunction of the fuse. Such failures cause high costs, down-time,degraded perception of the product embodying the system, potentiallydangerous situations or stranding due to power loss, and the like.Designing a larger fuse to avoid nuisance failures can impose theexternal system to increased risk of an overcurrent event, and/orsignificant costs to upgrade the rest of the power system. Additionally,design of a system for multiple maximum power availabilities (e.g., onepower system for two different power ratings) requires that the fuseplan be altered or designed to accommodate multiple systems. In certainembodiments, the same hardware may be utilized for different powerratings, and/or changed after the system is in operation, providing foran off-nominal fuse sizing for at least one of the multiple powerratings.

Referencing FIG. 20, an example apparatus 1900 for providing additionalprotection against fuse nuisance faults and system failures isdescribed. The example apparatus 1900, for example implemented on thecontroller 214, includes a current event determination circuit 1902 thatdetermines a current event 1904 is active or predicted to occur, wherethe current event includes a component experiencing (or about toexperience) a wear event—such as a current value that will cause thermaland/or mechanical stress on the component but may not cause an immediatefailure or observable damage. An example component includes the fuse,but may be any other component in the system including a battery cell, aswitch or connector, a motor, etc. Another example current eventincludes a system failure value—for example a current value that willpossibly or is expected to cause a system failure (e.g., a cablefailure, connector failure, etc.).

The apparatus 1900 further includes a response determination circuit1906 that determines a system response value 1910 to the current event1904. Example and non-limiting responses include notifying an operatorto reduce power, reducing power, notifying a system controller that acurrent event 1904 is present or imminent, opening a contactor on thecircuit related to the event, delaying circuit protection, monitoringthe event and a cause for response delay and responding at a later time,and/or scheduling a response according to an operating condition in thesystem. The apparatus 1900 further includes a response implementationcircuit 1908, where the response implementation circuit 1908 determinescommunications and/or actuator responses according to the systemresponse value 1910, and provides network communications 1912 and/oractuator commands 1914 to implement the system response value 1910.Example and non-limiting actuator responses include operating acontactor, operating an active coolant actuator to modulate thermalconduction away from the fuse, or the like.

Referencing FIG. 21, illustrative data 2000 for implementing a systemresponse value 1910 is depicted. The illustrative data 2000 includes athreshold value 2002—for example a current, temperature, indexparameter, or other value at which component wear and/or system failureis expected to occur, and utilized as a threshold by the current eventdetermination circuit 1902—at least under certain operating conditionsat a point in time for the system. It is understood that the currentevent determination circuit 1902 may utilize multiple thresholds, and/ordynamic thresholds, as described throughout the present disclosure. Thecurve 2004 represents the nominal system performance, for example thecurrent, temperature, index parameter, or the like that will beexperienced by the system in the absence of operations of the apparatus1900. In the example, the response determination circuit 1906 determinesthat the threshold value 2002 will be crossed, and accounts for acontactor disconnection time 2008 (and/or an active coolant loopresponse time), commanding the contactor and/or increasing thermalconduction away from the fuse, in time to avoid crossing the thresholdvalue 2002. The illustrative data 2000 depicts a resulting systemresponse curve 2006, wherein the resulting system performance is keptbelow the threshold value 2002. The system may experience alternativeresponse trajectories (e.g., the resulting system response curve 2006may fall well below the threshold value 2002 depending upon the dynamicsof the system, how long the contactor is kept open, etc.). Additionallyor alternatively, the response determination circuit 1906 maynevertheless allow the threshold value 2002 to be crossed, for exampleaccording to any operations or determinations described throughout thepresent disclosure. In certain embodiments, the response determinationcircuit 1906 allows the threshold value 2002 to be crossed, but resultsin a lower peak value of the response, and/or a lower area under theresponse curve that is above the threshold value 2002, than would occurwithout the operations of the response determination circuit 1906.

An example procedure, which may be performed by an apparatus such asapparatus 1900, includes an operation to determine that a current event(or other response event) is exceeding or predicted to exceed a wearthreshold value, and/or determining that the current event is exceedingor predicted to exceed a system failure value. In response todetermining the current event is exceeding or predicted to exceed eithervalue, the procedure includes an operation to perform a mitigatingaction. The component for the wear threshold value may be a fuse (e.g.,the fuse is experiencing or expected to experience a current event thatwill cause mechanical stress, thermal stress, or high usage of the fuselife), a component in the system (e.g., a contactor, a cable, a switch,a battery cell, etc.), and/or a defined threshold value that isnominally determined (e.g., calibration for a value that is expected tobe relevant to possible component damage, without being necessarily tiedto a specific component). In certain embodiments, the wear thresholdvalue and/or the system failure value are compensated for the age orwear state of the system or a component in the system (e.g., thresholdsare reduced, and/or responses are increased, as the system ages).

Non-limiting mitigating actions, which may be system response values1910, include, without limitation: 1) disconnecting a circuit having thewear component (e.g., the fuse, system component, and/or the specificpower line experiencing the event); 2) notifying an operator to reduce apower request; 3) notifying a vehicle or powertrain controller of thecurrent event; 4) adjusting or limiting available power to the operator;5) delaying circuit protection (disconnection and/or power reduction) inresponse to circumstances (e.g., in traffic, moving vehicle, applicationtype, notification from an operator that continued operation isrequired, etc.)—including allowing a component in the system toexperience the underlying wear event and/or failure event; 6) continuedmonitoring and disconnecting the circuit (or reducing power, etc.) ifthe event persists and if later conditions allow; 7) scheduling theresponse according to an operating mode of the system (e.g., sport,economy, emergency, fleet operator (and/or policy), owner/operator(and/or policy), geographic policy, and/or regulatory policy); and/or 8)bypassing the wear component (e.g., bypassing current around a fuse as aresponse action).

In certain embodiments, the operation to determine that the currentevent is exceeding the wear threshold value and/or the system failurevalue is based upon a calculation such as: 1) determining the currentthrough the circuit exceeds a threshold value (e.g., an amp value); 2)determining a rate of change of the current through the circuit exceedsa threshold value (e.g., an amp/second value); and/or 3) determiningthat an index parameter exceeds a threshold value (e.g., the indexincluding accumulated amp-seconds; amp/sec-seconds; a counting index forperiods above a threshold value or more than one threshold value; acounting index weighted by the instantaneous current value; anintegrated current, heat transfer, and/or power value; and/or countingdown or resetting these based on current operating conditions).

In certain embodiments, the operation to determine that the currentevent is exceeding the wear threshold value and/or the system failurevalue includes or is adjusted based upon one or more of: 1) a trip curve(e.g., a power-time or current-time trajectory, and/or an operatingcurve on a data set or table such as that represented in FIG. 3); 2) afuse temperature model, including a first or second derivative of thetemperature, and one or more temperature thresholds for scheduled and/orescalating response; 3) a measured battery voltage (e.g., current valuesmay be higher as battery voltage lowers, and/or dynamic response ofcurrent may change causing changes for the wear threshold value, systemfailure value, and/or current event determination); 4) a firstderivative of current, temperature, power demand, and/or an indexparameter; 5) a second derivative of current, temperature, power demand,and/or an index parameter; 6) information from a battery managementsystem (e.g., voltage, current, state of charge, state of health, rateof change of any of these, which parameters may affect current values,expected current values, and/or dynamic response of current values,causing changes for the wear threshold value, system failure value,and/or current event determination); 7) determination of and monitoringof contactor disconnect times, and accounting for the contactordisconnect time in determining the response to the current event; 8)utilizing ancillary system information and adjusting the response (e.g.,a power request from operations that is expected to create an upcomingchange, a supplemental restraint system active/deploying—open contactors(cut power); collision avoidance system active—keep contactors closedfor maximum system control; and/or an anti-lock brake system and/ortraction control system active—keep contactors closed for maximum systemcontrol). In certain embodiments, a degree of activation may also beconsidered, and/or system status may be communicated to the PDU—forexample the system may report critical operation requiring power as longas possible, or shut-down operations requiring power to be cut as soonas possible, etc.

Referencing FIG. 22, an example apparatus 600 to measure current througha fuse utilizing active current injection is schematically depicted. Theapparatus 600 includes the controller 214 having a number of circuitsconfigured to functionally execute operations of the controller 214. Thecontroller 214 includes an injection control circuit 602 that providesan injection command 604, where the current source 220 is responsive tothe injection command 604. The controller 214 further includes aninjection configuration circuit 606 that selects a frequency, amplitude,and/or waveform characteristic (injection characteristic 608) for theinjection command 604. The controller 214 further includes a duty cycledescription circuit 610 that determines a duty cycle 612 for a systemincluding the controller 214, where the duty cycle includes adescription of currents and voltages experienced by the fuse. In certainembodiments, the duty cycle description circuit 612 further updates theduty cycle 612, for example by observing the duty cycle over time, overa number of trips, over a number of operating hours, and/or over anumber of miles traveled. In certain embodiments, the duty cycledescription circuit 612 provides the duty cycle as an aggregated dutycycle, such as a filtered duty cycle, averaged duty cycle, weightedaverage duty cycle, bucketed duty cycle with a quantitative descriptionof a number of operating regions, or the like, and selects or mixes acalibration from a number of calibrations 614, each calibrationcorresponding to a defined duty cycle.

An example procedure to determine fuse current throughput is describedfollowing. In certain embodiments, one or more aspects of the proceduremay be performed by an apparatus 600. The procedure includes anoperation to inject a current having a selected frequency, amplitude,and/or waveform characteristic into the circuit through the fuse, and toestimate the fuse resistance (including dynamic resistance and/orimpedance) in response to the measured injected AC voltages and theinjected current. In certain embodiments, the selected frequency,amplitude, and/or waveform characteristic is selected to provide for anacceptable, improved, or optimized measurement of the fuse resistance.For example, the base power current through the fuse to supportoperations of the application have a certain amplitude and frequencycharacteristic (where frequency includes both the power frequency if AC,and the long term variability of the amplitude if AC or DC). Theinjected current may have a selected frequency and/or amplitude to allowfor acceptable detection of the fuse resistance in view of the basepower current characteristics, and also selected to avoid interferencewith the operations of the application. For example, if the base powercurrent is high, a higher amplitude of the injection current may beindicated, both to support measurement of the injected AC voltage, andbecause the base power current will allow for a higher injected currentwithout interfering with the operations of the system. In anotherexample, a frequency may be selected that is faster than currentvariability due to operations, that does not impinge upon a resonantfrequency or harmonic frequency of a component in the system, or thelike.

An example procedure includes storing a number of calibration valuescorresponding to various duty cycles of the system (e.g.,current-voltage trajectories experienced by the system, bucketed timewindows of current-voltage values, etc.), determining the duty cycle ofthe system, and selecting a calibration value from the calibrationvalues in response to the determined duty cycle. The calibration valuescorrespond to the current injection settings for the current injectionsource, and/or to filter values for digital filters to measure the fusevoltage and/or fuse current values. In certain embodiments, the dutycycle can be tracked during operations, and updated in real-time or atshutdown. In certain embodiments, an aggregated duty cycle descriptionis stored, which is updated by data as observed. An example aggregatedduty cycle includes a moving average of the duty cycle observed (e.g., aduty cycle defined as a trip, power on to power off cycle, operatingtime period, and/or distance traveled), a filtered average of the dutycycle (e.g., with selected filter constants to provide the desiredresponse to a change—for example to respond within one trip, five trips,30 trips, one day, one week, one month, etc.). In certain embodiments,the duty cycle updates occur with a weighted average (e.g., longertrips, higher confidence determinations, and/or operator selections orinputs may be weighted more heavily in determining the duty cycle).

A response indicates the period until the system is acting substantiallybased upon the changed duty cycle information, for example wherecalibration A is for a first duty cycle and calibration B is for thechanged duty cycle, the system may be deemed to have responded to thechange when 60% of calibration B is utilized, 90% of calibration B isutilized, 96% of calibration B is utilized, and/or when the system hasswitched over to calibration B. The utilization of multiple calibrationsmay be continuous or discrete, and certain aspects of the calibrationsindividually may be continuous or discrete. For example, wherecalibration A is selected, a particular amplitude (or trajectory ofamplitudes), frequency (or trajectory of frequencies), and/or waveform(or number of waveforms) may be utilized, and where calibration B isselected, a different set of amplitudes, frequencies, and/or waveformsmay be utilized. Where a duty cycle is positioned between A and B,and/or where the duty cycle response is moving between A and B, thesystem can utilize mixtures of the A and B duty cycles, and/or switchbetween the A and B duty cycles. In a further example, the switchingbetween the A and B duty cycles can occur in a mixed fashion—for examplewhere the current response is at 80% of B, then calibration B may beutilized 80% of the time and calibration A may be utilized 20% of thetime. In certain embodiments, the calibration may be switched abruptlyat a certain threshold (e.g., at 70% response toward the newcalibration), which may include hysteresis (e.g., switch to calibrationB at 80% of the distance between calibration A and B, but switch backonly when at 40% of the distance between calibration A and B). Incertain embodiments, certain aspects (e.g., the amplitude) may movecontinuously between calibrations, where other aspects (e.g., thewaveform) utilize only one calibration or the other. In certainembodiments, indicators of quality feedback may be utilized to adjustthe calibration response (e.g., where, during movement towardcalibration B, the indicated fuse resistance appears to be determinedwith greater certainty, the system moves the response toward calibrationB more quickly than otherwise, which may include utilizing more ofcalibration B than indicated by the current aggregated duty cycle,and/or adjusting the aggregated duty cycle to reflect a greaterconfidence that the duty cycle is going to be maintained).

Example amplitude selections include both the peak amplitude of theinjected current, the adjustment from the baseline (e.g., higherincrease than decrease, or the reverse), and/or the shape of amplitudegeneration (e.g., which may be in addition to or incorporated within thewaveform selection). Additionally or alternatively, the amplitude for agiven calibration may be adjusted throughout a particular currentinjection event—for example to provide observations at a number ofamplitudes within the current injection event. Example frequencyselections include adjusting the frequency of the periods of the currentinjection events, and may further include testing at a number ofdiscrete frequencies, sweeping the frequencies through one or moreselected ranges, and combinations of these. Example waveform selectionsinclude waveform selections to induce desired responses, to be morerobust to system noise (e.g., variability in the base current,inductance and/or capacitance of components in the system, or the like),to enhance the ability of the current injection detection to isolate theinjected current from the load current, and/or may include utilizationof multiple waveforms in a given calibration to provide a number ofdifferent tests. In certain embodiments, where multiple amplitudes,frequencies, and/or waveforms are utilized, the injected AC voltage (andcorresponding fuse resistance) can be determined by averaging measuredparameters, by using higher confidence measurements, and/or byeliminating outlying measurements from the injected AC voltagedetermination.

According to the present description, operations to provide a highconfidence determination of a fuse resistance value in a PDU 102 aredescribed. In certain embodiments, the high confidence determination ofthe fuse resistance can be utilized to determine the fuse condition, toprovide a high accuracy or high precision determination of currentthrough the fuse and of power consumption by the system 100, and/or toperform system diagnostics, fault management, circuit management, or thelike.

Referencing FIG. 23, an example apparatus 700 to determine a null offsetvoltage and/or diagnose a system component are schematically depicted.The example apparatus 700 includes a controller 214 having a fuse loadcircuit 702 that determines that no current is demanded for a fuse load704. The example apparatus 700 further includes a null offset voltagedetermination circuit 706 that determines a null offset voltage 708 inresponse to the fuse load 704 indicating that no current is demanded.The example apparatus 700 further includes a component diagnosticcircuit 710 that determines whether a component is degraded, failed,and/or in a fault or off-nominal condition in response to the nulloffset voltage 708, and determines fault information 716 in response tothe determining whether a component is degraded, failed, and/or in afault or off-nominal condition (e.g., fault counters, fault values,and/or component-specific information). Operations of the componentdiagnostic circuit 710 include comparing the null offset nominal voltage708 to a null offset voltage threshold value 712, and/or performingoperations to determine which component is causing an off-nominal nulloffset voltage 708. The example apparatus 700 further includes a nulloffset data management circuit 714 that stores the null offset voltage708, and/or any diagnostic or fault information 706 such as faultcounters, fault values, and/or indications of which component is causingthe off-nominal null offset voltage 708. In certain embodiments, wherecontributions to the null offset voltage 708 are determined separatelyfor certain components, an example null offset data management circuit714 stores individual contributions of the null offset voltage 708separately. In certain embodiments, the utilization of the null offsetvoltage 708 improves the accuracy of determining the fuse resistancefrom the injected current.

An example procedure to determine null offset voltage for a fuse currentmeasurement system is described following. The example procedure may beperformed by a system component such as an apparatus 700. Null offsetvoltages occur in a controller 214 due to individual offsets of op-ampsand other solid state components in the controller 214, as well as dueto part-to-part variations, temperature drift, and degradation of one ormore components in the system over time. The presence of a null offsetvoltage limits the accuracy with which current measurement through afuse is available, and can thereby limit the types of controls anddiagnostics that can be performed in the system.

An example procedure includes an operation to determine that no currentis demanded for a fuse load. Example operations to determine that nocurrent is demanded for a fuse load include a recent key-on or key-offevent for a vehicle (e.g., the vehicle is starting, powering down, is inan accessory position, and/or has not yet engaged power to the fuse ofinterest), observation of the fuse circuit, and/or by a statusobservation provided by another controller in the system (e.g., apowertrain controller is explicitly indicating that no power is beingprovided, is indicating a status inconsistent with power being provided,etc.). An example operation determines that no current is demanded for afuse during a key-off event, and/or within a time period after a key-onevent.

The example procedure further includes an operation to determine thenull offset voltage in response to determining that no current isdemanded for the fuse load, and an operation to store the null offsetvoltage. In certain embodiments, the stored null offset voltage isstored in non-volatile memory, for example to be utilized in asubsequent operation of the system. In certain embodiments, the nulloffset voltage is stored in a volatile memory and utilized for a currentoperation cycle. The stored null offset voltage may be replaced when anew value is determined for the null offset voltage, and/or updated in ascheduled manner (e.g., by averaging in or filtering in updated values,by holding new values for subsequent confirmation before being applied,etc.).

An example procedure further includes diagnosing a component of thesystem in response to the null offset voltage. For example, as the nulloffset voltage increases over time, a degradation of the controller 214may be indicated, and a fault (visible or service available) may beprovided to indicate that the controller 214 is operating off-nominallyor failed. Additionally or alternatively, a contactor (e.g., the maincontactor 216) may be diagnosed in response to the null offset voltage.In certain embodiments, further operations such as engaging anothercontactor in-line with the diagnosed contactor may be utilized toconfirm which component of the system is degraded or failed. In certainembodiments, the controller 214 may cut power to one or more componentswithin the controller 214 to confirm that the controller 214 componentsare causing the offset voltage. In certain embodiments, the procedureincludes determining the individual contributions of components to theoffset voltage—for example by separating the controller 214 contributionand the contactor contribution. In response to the offset voltage beingabove a threshold value and/or confirming which component of the systemis causing the off-nominal offset voltage, the controller 214 mayincrement a fault value, set a fault value, and/or set a service ordiagnostic value. In certain embodiments, the null offset voltage and/orany fault values may be made available to the system, to a network,and/or communicated to another controller on the network.

According to the present description, operations to provide a nominaloffset voltage for high confidence determination of a fuse current and afuse resistance value in a PDU 102 are described. In certainembodiments, the high confidence determination of the fuse resistancecan be utilized to determine the fuse condition, to provide a highaccuracy or high precision determination of current through the fuse andof power consumption by the system 100, and/or to perform systemdiagnostics, fault management, circuit management, or the like.

Referencing FIG. 24, an example apparatus 800 to provide for digitalfiltering of a current measurement through a fuse circuit is depictedschematically. In certain embodiments, where current is injected througha fuse, the measurement of the base power current and the injected ACcurrent through the fuse are de-coupled utilizing a low-pass filter(pulling out the base power signal) and a high-pass filter (pulling outthe injected current signal). Previously known systems utilize an analogfilter system—for example constructed of capacitors, resistors, and/orinductive devices, that provide the selected filtering of the signal andthereby provide the separated base power signal and injected currentsignal. However, analog filter systems suffer from a number ofdrawbacks. First, analog systems are not configurable, are onlyconfigurable to a discrete number of pre-considered options, and/or areexpensive to implement. Accordingly, a wide range of base power signalsand injected AC current signals are not typically available for highaccuracy determination of the fuse current with an analog filter system.Additionally, analog filter systems suffer from phase variance betweenthe low-pass filter and the high-pass filter, and/or between thefiltered output and the injected current signal. Accordingly,post-processing and/or acceptance of a less accurate signal arerequired, and accuracy is diminished on the measured current even withpost-processing. Further, if the system has a component that has a basefrequency or harmonic that interferes with the filter, the analog filteris not able to respond and will not provide reliable measurements.Because the frequency dynamics of the system can change over time, forexample as components degrade, are service or replaced, and/or due toenvironmental or duty-cycle driven changes, even careful system designcannot fully resolve the inability of analog filters to respond tointerference from frequency dynamics in the system. The exampleapparatus 800 includes a high-pass digital filter circuit 802 thatdetermines the injected current value 804 for the fuse circuit byproviding a high-pass filter operation on a measured fuse current 814,and a low-pass digital filter circuit 806 that determines the base powercurrent value 808 for the fuse circuit by providing a low-pass filteroperation on the measured fuse current. The example apparatus 800further includes a filter adjustment circuit 812 that interprets a dutycycle 612 and/or an injection characteristic 608, and adjusts thefiltering for the high-pass digital filter circuit 802 and/or theinjection characteristic 608—for example by providing filter adjustments816 such as providing distinct cutoff frequencies to ensure separationof the signals, to raise or lower cutoff frequencies to ensure adescriptive energy portion of the signal is captured, and/or tomanipulate the filters to avoid a frequency or a harmonic in the system.While the example embodiment of FIG. 24 utilizes a digital filter, incertain embodiments the available controller processing resources and/ortime response of digital filtering may lead certain systems to utilizeanalog filters and/or a combination of analog filters with digitalfilters.

An example procedure includes an operation to provide digital filters ina PDU 102 to determine base power and injected current values from ameasured current value through the fuse. The example procedure furtherincludes an operation to determine the base power by performing alow-pass filter operation on the measured current value, and todetermine the injected current value by performing a high-pass filteroperation on the measured current value. The example procedure furtherincludes an operation to adjust parameters of the low-pass filter and/orthe high-pass filter in response to a duty cycle of the system includingthe PDU 102 (including, for example, power, voltage, and/or currentvalues passing through the fuse), and/or in response to an injectioncharacteristic of the injected current through the fuse. The exampleprocedure includes adjusting the parameters to improve the separation ofthe base power and/or injected current values, to improve the accuracyof determining the injected current amount, to adjust to a frequencyand/or a harmonic of a component in the system in electricalcommunication with the fuse, and/or to respond to a system orenvironmental noise affecting one or both of the high-pass and low-passfilters.

According to the present description, operations to implement digitalfilters for de-convoluting a voltage characteristic and currentmeasurement through a fuse are provided. The digital filtering allowsfor the system to provide a high confidence determination of a fusecurrent and a fuse resistance value in a PDU 102. In certainembodiments, the high confidence determination of the fuse resistancecan be utilized to determine the fuse condition, to provide a highaccuracy or high precision determination of current through the fuse andof power consumption by the system 100, and/or to perform systemdiagnostics, fault management, circuit management, or the like.

Fuses for highly transient load applications and/or high duty cyclevariability applications, such as but not limited to electrical systemsfor mobile applications and vehicles experience a number of challenges.Load variation can change considerably throughout operations, includingexperiencing both high positive and high negative current operations,and often in a short period of time (e.g., acceleration and regenerativebraking cycles in stop-and-go traffic; high load operation going up ahill followed by significant regeneration down the other side, etc.).Additionally, current transients and reversals can result in significantin-rush currents that are experienced by the fuse. Fuses are designed tofail at a protective current value, which is intended to correspond to afuse temperature value. Because they are designed to fail at arelatively close value to the maximum current demands, they areconsequently one of the most delicate physical parts in the system—bothelectrically and physically. Sub-critical current values and currenttransient values can cause the fuse to suffer thermal and mechanicalstresses, both from temperatures experienced and temperature transients.Fuses subject to significant sub-critical cycling can fail—either bymelting even though the designed failure current has not been exceeded,or by breaking due to mechanical stress. Mobile applications, asdiscussed throughout the present disclosure, are subject to particularlyhigh costs and risks when a mission critical component such as a fusefails (e.g., the vehicle generally does not have motive power availableif a main power fuse fails). Additionally, mobile applications aresubject to high transient loads through the motive power system.

Referencing FIG. 25, an example fuse circuit 2100 is depicted, which maybe present on a PDU 102. The example fuse circuit 2100 may be associatedwith a main fuse, an auxiliary fuse, and/or a group of fuses or a subsetof a group of fuses. The fuse circuit 2100 includes a contactor (C1) inparallel with the fuse (F1). During normal operations the contactor isopen, and the current in the fuse circuit 2100 passes through the fuse.In certain embodiments, the contactor may include physical components(e.g., a solenoid and/or coil-based switch or relay), and/or thecontactor may be a solid state relay. In certain embodiments, thecontactor may be normally-open (e.g., power applied closes thecontactor) or normally-closed (e.g., power applied opens the contactor).The example fuse circuit 2100 allows for the contactor to selectivelybypass the fuse circuit, for example in accordance with operations of anapparatus 1900 (reference FIG. 20 and the corresponding disclosure).

Referencing FIG. 26, another embodiment of a fuse circuit 2200 isdisclosed, with a contactor (C1) in series with a second fuse (F2), andthe C1-F2 branch in parallel with a first fuse F1. The fuse circuit 2200provides for additional flexibility and a number of additional featuresfor operations of an apparatus 1900. For example, normal operation maybe performed with the contactor closed, dividing current between F1 andF2 (in the resistance ratios of the two fuses). An example includes afuse F2 with a low current threshold value, set such that the dividedcurrent would fail fuse F2 if the system design current is exceeded by adesigned amount (e.g., between 135% and 300% of system designcurrent—although any value is contemplated herein). The fuse F1 may beset at a very high value, allowing for the opening of the contactor tobriefly increase the fusing capacity of the circuit but still be fused.Additionally or alternatively, fuse F2 may be a relatively cheap and/oraccessible fuse, and being at a lower current threshold F2 is likely tosuffer greater mechanical and thermal fatigue, and act as the failurepoint for the fuse circuit 2200, which may greatly extend the life ofthe fuse F1 which may be more expensive and/or less accessible.Additionally or alternatively, normal operation may be performed withthe contactor open, with fuse F1 defining the ordinary fusing of thecircuit. When a high transient or other current event occurs, thecontactor is closed, and the branch C1-F2 shares the current load,keeping the fuse F1 within normal or lower wear operating conditions. Incertain embodiments, fuses F1 and F2 may be similarly sized—for exampleto allow fuse F2 to operate as a backup fuse and to keep similar failureconditions in place for F1 and F2. Alternatively, fuse F2 may be smallerthan fuse F1, allowing for alternate operations as described, theintermittent use of the C1-F2 circuit to take up some current to protectfuse F1, and/or to provide back-up fusing for F1—which may be at areduced power limit for the system if the fuse F2 is smaller (e.g., as ade-rated mode of operation, and/or a limp-home mode of operation).Alternatively, fuse F2 may be larger than fuse F1, for example to allowfuse F2 to manage very high transient current conditions where it isdesired that operation still continues. The utilization of a fusecircuit 2200 allows for a high degree of control of the fusing system,to be protective of the power system during nominal operation and stillprovide a high degree of capability during failure modes, foroff-nominal operation, and/or during transient operation. In certainembodiments, a resistor may be provided on the C1-F2 branch, for exampleto control the current sharing load between F1 and F2 when the contactorC1 is closed.

Referencing FIG. 27, a fuse circuit 2300 includes a plurality of fusesF1, F2, F3, F4 depicted in parallel, with a corresponding contactor inseries with each. An example fuse circuit 2300 is for auxiliary fuses,although fuse circuit 2300 can be any fuse, including a main fuse. Theexample fuse circuit 2300 allows for either the removal of fuses fromoperation—for example where one of the fuses is experiencing a transientevent—or for the addition of fuses, such as when a high transient eventoccurs to share the current load. In certain embodiments, one or more ofthe fuses in the fuse circuit 2300 does not have an associatedcontactor, and is a primary load bearing fuse for the fuse circuit 2300.The relative sizing of the fuses in the fuse circuit 2300 may beaccording to any selected values, and will depend upon the purpose ofthe fuse circuit 2300 (e.g., to provide a limp-home feature, to provideadditional capacity, to act as a back-up, and/or to allow for thecut-off of individual fuses in the system). Additionally oralternatively, any one or more of the fuses in fuse circuit 2300 may bepositioned serially with a resistor, for example to control current loadbalancing. In certain embodiments, the fuses F1, F2, F3, F4 are not inparallel, and/or one or more of the fuses is not in parallel.Accordingly, the opening of a contactor for such a fuse will not shuntcurrent to another one of the fuses. An example embodiment includes thecontactors for fuses individually to allow for shutting down of certainsystem capability (e.g., due to a failure, high transient, or the like)without shutting down all system capability (e.g., a fuse supportingbraking may remain active even in a high transient event, while anaccessory fuse for non-critical systems may be cut off to protect thefuse and/or the system).

Referencing FIG. 28, a fuse circuit 2400 is depicted, similar to fusecircuit 2300, except that each fuse has a contactor in parallel,allowing for the shorting of the particular fuse while keeping currentflowing on that fuse's path. In certain embodiments, the parallel pathfor each fuse may include an additional fuse and/or a resistor, suchthat when the fuses are connected in parallel, the load across each fusecircuit remains at least partially balanced. The embodiments of FIGS. 25to 28 may be referenced as current protection circuits, and embodimentssuch as those depicted in FIGS. 25 to 28, and/or as described, allow forselectable configuration of the current protection circuit. Selectableconfiguration of the current protection circuit may include run-timeoperations (e.g., reconfiguring the current protection circuit inresponse to events or operating conditions) and/or design-timeoperations (e.g., allowing a same hardware device to support multiplepower ratings, electrical connection configurations, and/or serviceevent or upgrade changes).

Referencing FIG. 29, illustrative data 2500 showing a fuse response to adrive cycle for a vehicle is depicted. In the example, fuse current(e.g., the dashed line lower curve at times of 12 and 25 units) and fusetemperature (e.g., the solid line upper curve at times of 12 and 25units) are depicted. It will be understood that another parameterdescribing the fuse performance and/or limits may be utilized, includingat least any values described in the portion referencing FIG. 21. Theoperations of the drive cycle exhibit high transients where, in theexample, the fuse temperature is expected to exceed the “fusetemperature avoidance limit”—for example, a temperature or temperaturetransient at which the fuse experiences mechanical stress. An apparatus1900 may consider a number of thresholds for the fuse—for example alight wear threshold, a heavy wear threshold, and a potential failurethreshold, which may be set at distinct values of the fuser performanceindicator being utilized (e.g., temperature). In certain embodiments,more than one type of threshold value may be utilized—for example athreshold or set of thresholds for temperature, a second threshold orset of thresholds for temperature change with time (e.g., dT/dt), etc.In the example, an apparatus 1900 may take mitigating action at thetransient points, for example bypassing the corresponding fuse brieflyto avoid the transient and/or control the rate of transient experiencedby the fuse.

Referencing FIG. 30, an example system 2600 include the power source 104and load 106, with a fuse (F1) electrically disposed between the load106 and the source 104. An operator provides a power request(accelerator pedal input), and an apparatus 1900 determines that theload request will exceed a threshold for the fuse (e.g., according tothe current demand above temperature limit, or some other determination)but may further determine that the transient event will not otherwiseexceed system operating condition limits. In the example, apparatus 1900commands the contactor (C3) to close for a period of time before orduring the transient to protect the fuse. The system 2600 depicts thehigh-side (C1) and low-side (C3) high voltage contactors (e.g., 216, 218from system 100), which are distinct from the fuse bypass contactor C3.

Referencing FIG. 21, illustrative data 2000 for implementing a systemresponse value 1910 is depicted. The illustrative data 2000 includes athreshold value 2002—for example a current, temperature, indexparameter, or other value at which fuse wear and/or failure is expectedto occur, and utilized as a threshold by the current event determinationcircuit 1902—at least under certain operating conditions at a point intime for the system. It is understood that the current eventdetermination circuit 1902 may utilize multiple thresholds, and/ordynamic thresholds, as described throughout the present disclosure. Thecurve 2004 represents the nominal system performance, for example thecurrent, temperature, index parameter, or the like that will beexperienced by the fuse in the absence of operations of the apparatus1900. In the example, the response determination circuit 1906 determinesthat the threshold value 2002 will be crossed, and accounts for acontactor connection/disconnection time 2008 (e.g., to bypass the fuse,engage a second fuse branch, and/or close off a more vulnerable fusebranch), commanding the contactor to connect or disconnect in time toavoid crossing the threshold value 2002. Additionally or alternatively,the response determination circuit 1906 may nevertheless allow thethreshold value 2002 to be crossed, for example according to anyoperations or determinations described throughout the presentdisclosure—for example when a more critical system parameter requiresthe fuse to remain connected, and the fuse is allowed to experience thewear and/or failure event.

In certain embodiments, the operation to determine that the currentevent is exceeding the wear threshold value and/or the fuse failurevalue is based upon a calculation such as: 1) determining the currentthrough the fuse exceeds a threshold value (e.g., an amp value); 2)determining a rate of change of the current through the fuse exceeds athreshold value (e.g., an amp/second value); 3) determining that anindex parameter exceeds a threshold value (e.g., the index includingaccumulated amp-seconds; amp/sec-seconds; a counting index for periodsabove a threshold value or more than one threshold value; a countingindex weighted by the instantaneous current value; an integratedcurrent, heat transfer, and/or power value; and/or counting down orresetting these based on current operating conditions).

In certain embodiments, the operation to determine that the currentevent is exceeding the wear threshold value and/or the fuse failurevalue includes or is adjusted based upon one or more of: 1) a trip curve(e.g., a power-time or current-time trajectory, and/or an operatingcurve on a data set or table such as that represented in FIG. 3); 2) afuse temperature model, including a first or second derivative of thetemperature, and one or more temperature thresholds for scheduled and/orescalating response; 3) a measured battery voltage (e.g., current valuesmay be higher as battery voltage lowers, and/or dynamic response ofcurrent may change causing changes for the wear threshold value, systemfailure value, and/or current event determination); 4) first derivativeof current, temperature, power demand, and/or an index parameter; 5)second derivative of current, temperature, power demand, and/or an indexparameter; 6) information from a battery management system (e.g.,voltage, current, state of charge, state of health, rate of change ofany of these, which parameters may affect current values, expectedcurrent values, and/or dynamic response of current values, causingchanges for the wear threshold value, fuse failure value, and/or currentevent determination); 7) determination of and monitoring of contactorconnection or disconnection times, and accounting for the contactorconnection or disconnection time in determining the response to thecurrent event; 8) utilizing ancillary system information and adjustingthe response (e.g., collision avoidance system active—allow the fuse tofail, and/or bypass the fuse allowing potential damage to the system, tokeep power flowing; anti-lock brake system and/or traction controlsystem active—keep power flowing for maximum system control (degree ofactivation may also be considered, and/or system status communicated tothe PDU—for example the system may report critical operation requiringpower as long as possible, or shut-down operations requiring power to becut as soon as possible, etc.)).

Referencing FIG. 20, an example apparatus 1900 to reduce or prevent fusedamage and/or a fuse failure is depicted. The example apparatus 1900includes a current event determination circuit 1902, which may determinethat current event 1904 indicates that a fuse threshold value (wear,failure, fatigue, or other threshold value) is exceeded or is predictedto be exceeded. The current event 1904 may be a current, temperature, orany other parameter described, for example, in relation to FIGS. 21, 29,and 30. The example apparatus 1900 further includes a responsedetermination circuit 1906 that determines a system response value1910—for example opening or closing one or more contactors in a fusecircuit (e.g., 2100, 2200, 2300, 2400, or any other fuse circuit orcurrent protection circuit). The apparatus 1900 further includes aresponse implementation circuit 1908 that provides networkcommunications 1912 and/or actuator commands 1914 in response to thesystem response value 1910. For example, the system response value 1910may determine to close one or more contactors, and the actuator commands1914 provides commands to the selected contactors which are responsiveto the actuator commands 1914.

In certain embodiments, operations to bypass and/or engage one or morefuses are performed in coordination with a vehicle battery managementsystem and/or an accelerator pedal input (or other load requestindicator)—for example to time inrush currents that would be experiencedon the fuses, to provide an indication to the battery management systemor other vehicle power systems that momentary un-fused operation isgoing to occur, and/or that a higher fuse limit will be brieflyapplicable. In certain embodiments, during un-fused operation and/orhigher fuse limit operation, the apparatus 1900 may operate a virtualfuse—for example if the experienced current is higher than predicted(e.g., it was predicted to exceed a fuse wear limit but be less than asystem failure limit, but in fact appears that a system failure limitwill be exceeded), the apparatus 1900 may operate to open a main highvoltage contactor, re-engage the fuse, or make another system adjustmentto protect the system in the absence of ordinarily available fusingoperations.

Referencing FIG. 31, an example apparatus 900 to determine an offsetvoltage to adjust a fuse current determination are schematicallydepicted. The example apparatus 900 includes a controller 214 having afuse load circuit 702 that determines that no current is demanded for afuse load 704, and further determines that contactors associated withthe fuse are open. The example apparatus 900 further includes an offsetvoltage(s) determination circuit 906 that determines offset voltages forcomponents in the fuse circuit observed during the no current demandedportion of the operating cycle. In certain embodiments, the contactorsremain open while pre-charge capacitors are still charging after akey-on cycle, whereupon the fuse load circuit 702 determines that nocurrent is demanded for the fuse load 704. In certain embodiments, thecontactors are opened during an operation of the system, and an examplefuse load circuit 702 determines that no current is demanded for a fuseload 704, including potentially waiting for observed voltages to settlebefore determining that no current is demanded for the fuse load 704.

The example apparatus 900 further includes an offset data managementcircuit 914 that stores the offset voltages 906, and communicatescurrent calculation offset voltages 904 for use in the system todetermine current flow through the one or more fuses in the system. Thecurrent calculation offset voltages 904 may be the offset voltages 906for the applicable components, and/or may be processed or conditionedvalues determined from the offset voltages 906.

An example procedure to determine an offset voltage for a fuse currentmeasurement system is described following. The example procedure may beperformed by a system component such as an apparatus 900. Offsetvoltages occur in a controller 214 due to individual offsets of op-ampsand other solid state components in the controller 214, as well as dueto part-to-part variations, temperature drift, and degradation of one ormore components in the system over time. The presence of an offsetvoltage limits the accuracy with which current measurement through afuse is available, and can thereby limit the types of controls anddiagnostics that can be performed in the system.

An example procedure includes an operation to determine that no currentis demanded for a fuse load. Example operations to determine that nocurrent is demanded for a fuse load include a recent key-on or key-offevent for a vehicle (e.g., the vehicle is starting, powering down, is inan accessory position, and/or has not yet engaged power to the fuse ofinterest), observation of the fuse circuit, and/or by a statusobservation provided by another controller in the system (e.g., apowertrain controller is explicitly indicating that no power is beingprovided, is indicating a status inconsistent with power being provided,etc.). An example operation determines that no current is demanded for afuse during a key-off event, and/or within a time period after a key-onevent.

The example procedure further includes an operation to determine theoffset voltage in response to determining that no current is demandedfor the fuse load, and an operation to store the offset voltage. Incertain embodiments, the stored offset voltage is stored in non-volatilememory, for example to be utilized in a subsequent operation of thesystem. In certain embodiments, the offset voltage is stored in avolatile memory and utilized for a current operation cycle. The storedoffset voltage may be replaced when a new value is determined for theoffset voltage, and/or updated in a scheduled manner (e.g., by averagingin or filtering in updated values, by holding new values for subsequentconfirmation before being applied, etc.).

According to the present description, operations to provide an offsetvoltage for components in the fuse circuit, for high confidencedetermination of a fuse current and a fuse resistance value in a PDU 102are described. In certain embodiments, the high confidence determinationof the fuse resistance can be utilized to determine the fuse condition,to provide a high accuracy or high precision determination of currentthrough the fuse and of power consumption by the system 100, and/or toperform system diagnostics, fault management, circuit management, or thelike.

Referencing FIG. 32, an example apparatus 1000 to provide unique currentwaveforms to improve fuse resistance measurement for a PDU 102 isschematically depicted. The example apparatus 1000 includes a fuse loadcircuit 702 that determines that no current is demanded for a fuse load704, and further determines that contactors associated with the fuse areopen. The example apparatus 1000 further includes an injectionconfiguration circuit 606 that determines injection characteristics 608,including frequency, amplitude, and waveform characteristics for testinjection currents through one or more fuses to be tested. The exampleapparatus 1000 further includes an injection control circuit 602 thatinjects current through the fuses according to the injectioncharacteristics 608, and a fuse characterization circuit 1002 thatdetermines one or more fuse resistance(s) 1004 in response to themeasured values 1006 during the test. An example injection controlcircuit 602 waits for the determination of voltage offset values whilethe fuse load 704 is still zero, and the fuse characterization circuit1002 further utilized the voltage offset values in determining the fuseresistance(s) 1004 for the fuses. In certain embodiments, the injectionconfiguration circuit 606 determines injection characteristics 608 inresponse to the characteristics of the system (e.g., the inherentcapacitance and/or inductance of the system, the size of the fuse, thecurrent ranges of the system during operation, and/or the resistancerange and/or desired precision to support operations determinationsutilizing the fuse resistance value). In certain embodiments, a highaccuracy of the fuse resistance supports diagnostics, fuse protectioncontrol, and/or high accuracy on battery state of charge determinations.

In certain embodiments, the fuse characterization circuit 1002determines the fuse resistance(s) 1004 for a given response based upon anumber of current injection events, each of which may have a distinctone or more of an amplitude, frequency, and/or waveform. Additionally oralternatively, frequency sweeping, amplitude sweeping, and/or waveformshape management may be manipulated between injection events and/orwithin a given injection event. The fuse characterization circuit 1002determines the fuse resistance 1004 by determining, for example, anaveraged resistance value determined over the course of the tests. Incertain embodiments, the fuse characterization circuit 1002 utilizesonly a portion of each test window—for example to allow circuit settlingtime after an injection characteristic 608 switch, to allow for theinjection provision circuit (e.g., a solid state op-amp, PWM, relay, orthe like, which is configured to provide a selected current through thefuse circuit) to settle after switching the injection characteristic608, to utilize a selected amount of data from each of the tests (e.g.,for weighting purposes), and the like. In certain embodiments, the fusecharacterization circuit 1002 may exclude outlying data (e.g., two ofthe tests agree, but a third test provides a far different value),and/or data which appears to indicate a rapid change which may appear tonot be valid data. In certain embodiments, filtering, moving averages,rolling buffers, counters for delay in switching values (e.g., toconfirm that a new value appears to be a real change) and the like areapplied by the fuse characterization circuit 1002 to the fuse resistance1004 to smooth changing values of the fuse resistance 1004 over timeand/or to confirm that new information is repeatable. In certainembodiments, each period or a group of periods of a given injectionwaveform may be treated as a separate data point for resistancedeterminations. In certain embodiments, for example where the amplitudeis swept for a given waveform, and/or where the frequency is swept for agiven waveform, the resistance contribution for a given period may alsobe weighted (e.g., higher amplitudes and/or lower frequencies providefor a lower designed area under the current-time curve—see, e.g. FIG.35—which may provide a higher quantity of information about theresistance relative to a lower amplitude and/or higher frequency periodof the same waveform). Additionally or alternatively, measurementconfidence may be dependent upon the frequency and/or amplitude of thecurrent injection, and accordingly resistance determinations for thoseinjection events may be weighted accordingly (e.g., given lower weightwith lower confidence, and higher weight with higher confidence).Additionally or alternatively, conformance of the current injectionsource may be dependent upon the frequency, amplitude, and/or waveformof the current injection, and accordingly resistance determinations forthose injection events may be weighted accordingly, and/or adjusted byfeedback on the injector outlet about what frequency, amplitude, and/orwaveform was actually provided relative to what was commanded.

In certain embodiments, the resistance determinations made by the fusecharacterization circuit 1002, including how the resistance isdetermined and the average indicated by a given test, depend upon thewaveform and other parameters. For example, if a sine wave waveform isutilized, resistance may be determined from the area under the voltageand current curves, from an rms determination (for current and/orvoltage), and/or from high resolution time slices within the voltagedeterminations utilizing the injected current characterization. Otherwaveforms will utilize similar techniques for determining theresistance. If the circuit exhibits significant impedance (e.g. fromlatent capacitance and/or inductance, and/or from components incommunication with the circuit that exhibit impedance), the impedancecan be calculated by varying the frequency and determining the commonimpedance effects between the tests. The availability of multiple testsutilizing varying amplitudes, waveforms, and/or frequency values ensuresthat high accuracy can be determined even for circuits with complexeffects or that exhibit changes due to age, degradation, or componentservicing or replacing. Further, adjusting the frequency throughout thetests, and/or sweeping the frequency for a given amplitude or waveformcan assist in de-coupling the phase-shifted aspects of impedance (e.g.,capacitance effects versus inductance effects) to more confidentlydetermine a resistance for the fuse. Typically for a fuse circuit havinga closely coupled current source, impedance will be minimal. The desireddegree of accuracy for the resistance measurement, which may depend uponthe diagnostics, battery state of charge algorithms, and/or fuseprotection algorithms in use on the system, may also affect whetherimpedance must be accounted for, and accordingly the selection ofinjection characteristics 608 utilized.

It can be seen that the use of multiple injection characteristics 608during a test leverages comparisons between the tests to de-couplesystem characteristics from the resistance determination, provides for arange of system excitement parameters to ensure that systemcharacteristics do not dominate a single test, and overall increase theamount of information available for a test to develop statisticalconfidence in the determined resistance value. Also, manipulation ofinjection characteristics 608 allows for better averaging—for example toprepare waveforms with high confidence that the resistance calculationis correct such as utilizing frequency values that avoid resonant orharmonic frequencies in the system, provide a large area under thecurrent-time (or voltage-time) curve, and/or provide for a stabilizedsystem during the test to ensure that measurement is correct.

Additionally or alternatively, the fuse characterization circuit 1002adjusts digital filter values before the test, between changes ininjection characteristics 608 for the test, and/or dynamically duringthe test (e.g., where a frequency sweep, amplitude sweep, and/orwaveform change is utilized during a given injection event). In certainembodiments, the measurement of the voltage out of the filter circuitutilizes a high-pass filter to determine the injection voltage (and/orcurrent), and the filter characteristics can be manipulated in real timeto provide for an appropriate filter, such as cutoff frequencies. Theutilization of digital filters for measurement can also eliminate phaselags between different filter types—such as a low pass filter and a highpass filter (e.g., where the low pass filter determines base powercurrent during operation, and/or confirms that base power currentremains zero or negligible during the test).

Referencing FIG. 35, an illustrative injection characteristic 608 isdepicted for an example test. The injection characteristic 608 includesa first injection portion having an amplitude of 10 current units (e.g.,amps—but any current units are contemplated herein), a sinusoidalwaveform, and a period of approximately 150 time units (e.g., executioncycles of the controller 214, milliseconds, seconds, or any otherparameter). The units and values depicted in FIG. 35 are non-limitingexamples, and are used to illustrate that sequential changes in theinjection characteristic 608 can be applied. The injectioncharacteristic 608 includes a second injection portion having anamplitude of 15 current units, a sawtooth waveform, and a period ofapproximately 250 time units. The injection characteristic 608 furtherincludes a third injection portion having an amplitude of 5 currentunits, a near square waveform (a slightly trapezoidal waveform isdepicted), and a period of approximately 80 time units. The embodimentdepicted in FIG. 35 is non-limiting, and other features may be added tothe test, including more or less than three distinct waveforms, gapsbetween waveforms, and adjustments within a waveform (includingsweeping, stepping, or otherwise adjusting frequency or amplitude,and/or adjusting the waveform itself). The example of FIG. 35 shows atrajectory reversal between the first and second injectioncharacteristic (e.g., decreasing sine wave to increasing sawtooth wave)and a continuation of the trajectory between the second and thirdinjection characteristic (e.g., decreasing sawtooth wave to anincreasing square wave), although any possibilities, including stepchanges of the current and the like, are contemplated herein.

Referencing FIG. 33, an example procedure 1100 to provide unique currentwaveforms to improve fuse resistance measurement for a PDU 102 isschematically depicted. The procedure 1100 includes an operation 1102 toconfirm that the contactors are open (and/or to confirm that the fuseload is zero or intended to be zero), and an operation 1104 to perform anull voltage offset determination—for example to determine offsetvoltage of op-amps and other components of the controller 214 and/or inthe system 100 electrically coupled to the fuse circuit. An exampleoperation 1102 is commenced during a key-on or system startup event withthe contactors open, although any operating condition meeting thecriteria for operation 1102 may be utilized. The procedure 1100 furtherincludes an operation 1106 to conduct a number of injectionsequences—for example three sequences each having a distinct frequency,amplitude, and waveform. The operation 1106 may include more than threesequences, and one or more of the sequences may share a frequency, anamplitude, and/or a waveform. The operation 1106 may be configured toperform as many sequences as desired, and may be carried over multipletests (e.g., where a test is interrupted by operations of the system orexceeds a desired time, the test may be continued on a later sequenceinitiated by operation 1102). The procedure 1100 further includes anoperation 1108 to determine fuse resistance values for one or more ofthe fuses in the system. The procedure 1100 may be operated onindividual fuses where hardware in the system is configured to supportthat, including across subsets of the fuses or the like.

Referencing FIG. 34, an example procedure 1106 to conduct a number ofinjection sequences is depicted. The example procedure 1106 includes anoperation 1202 to adjust injection characteristics for a currentinjection source associated with the fuse(s) to be tested, and anoperation 1204 to adjust filtering characteristics for one or moredigital filters associated with measuring voltage and/or current valueson the filtering circuit. The procedure 1106 further includes anoperation 1206 to perform the injection sequence in response to theinjection characteristic, and an operation 1208 to perform the filtering(e.g., thereby measuring the current and/or voltage on the fuse circuitin response to the injection events). The procedure 1106 furtherincludes an operation 1210 to determine if the current injectionsequence is completed, returning to continue the injection event atoperation 1206 until the sequence is complete (at operation 1210determining YES). For example, referencing FIG. 35, at time step 200 theoperation 1210 would determine NO, as the sine wave portion of the testis still being performed. If the operation 1210 determines YES (e.g., inFIG. 35, where the sine wave portion transitions to the sawtoothportion), the procedure 1106 includes an operation 1212 to determinewhether another injection sequence is desired, and returns to operation1202 to adjust the injection sequence in response to operation 1212determining YES (e.g., in FIG. 9, where the sine wave portion iscompleted and the sawtooth portion commences). In response to theoperation 1212 determining NO (e.g., where the square wave portion iscompleted, and no further sequences are scheduled in the test), theprocedure 1106 completes—for example returning to operation 1108 todetermine the fuse resistance value from the test.

According to the present description, operations to provide varyingwaveforms for current injection, thereby enhancing determination of thefuse resistance value in a PDU 102 are described. In certainembodiments, the high confidence determination of the fuse resistancecan be utilized to determine the fuse condition, to provide a highaccuracy or high precision determination of current through the fuse andof power consumption by the system 100, and/or to perform systemdiagnostics, fault management, circuit management, or the like.

Referencing FIG. 36, an example system includes a vehicle 3602 having amotive electrical power path 3604; and a power distribution unit 3606having a current protection circuit 3608 disposed in the motiveelectrical power path 3604. The example current protection circuit 3608includes a first leg 3610 of the current protection circuit 3608including a pyro-fuse 3620 (e.g., a controllable activated fuse that canbe commanded to activate and open the first leg of the currentprotection circuit; a second leg 3612 of the current protection circuit3608 including a thermal fuse 3622; and where the first leg 3610 and thesecond leg 3612 are coupled in a parallel arrangement (e.g., in asimilar manner to the depiction of any one of FIGS. 26 to 28). Theexample system includes a controller 3614 having a current detectioncircuit 3616 structured to determine a current flow through the motiveelectrical power path 3614, and a pyro-fuse activation circuit 3618structured to provide a pyro-fuse activation command in response to thecurrent flow exceeding a threshold current flow value. The pyro-fuse3620 is responsive to the pyro-fuse activation command, for example toactivate and open the second leg 3612 upon command. Upon activation ofthe pyro-fuse 3620, the second leg 3612 is opened, providing for normalfused operation on the first leg 3610 (e.g., thermal failure of thethermal fuse 3622 thereby opens the motive electrical power path 3604),and/or opening the motive electrical power path 3604 directly when acontactor 3626 in series with the thermal fuse 3622 is already opened.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes where a first resistance through the first leg3620 and a second resistance through the second leg 3612 are configuredsuch that a resulting current through the second leg 3612 after thepyro-fuse 3620 activates is sufficient to activate the thermal fuse3622. For example, a high current event may be experienced such that, ifthe second leg 3622 were not drawing a portion of the high currentevent, the thermal fuse 3622 would be activated. In the example, theopening of the second leg 3612 will cause the current in the first leg3620 to increase and activate the thermal fuse 3622. An example includesa resistor 3624 coupled in a series arrangement with the thermal fuse3622, such that a resulting current through the second leg 3612 afterthe pyro-fuse 3620 activates is below a second threshold current flowvalue. For example, an undersized thermal fuse 3622 may be utilized inthe system, with the operating current through the second leg 3612reduced by the resistor 3624. When the pyro-fuse 3620 opens, the currentthrough the second leg 3612 is increased, but still reduced by theresistor 3624 to prevent high current transients in the motiveelectrical power path 3604, and still allowing sufficient currentthrough the second leg 3612 to activate the thermal fuse 3622.

An example system includes a contactor coupled 3626 in a seriesarrangement with the thermal fuse 3622, the controller further includinga contactor activation circuit 3628 structured to provide a contactoropen command in response to at least one of the pyro-fuse activationcommand or the current flow exceeding the threshold current flow value.In certain embodiments, the contactor 3626 coupled in the seriesarrangement with the thermal fuse 3622 allows for control of the currentthrough the second leg 3612, including opening the second leg 3612 toopen the motive electrical power path 3604 in combination withactivation of the pyro-fuse 3620. The resistor 3624 may additionally beutilized with the contactor 3626, for example reducing the currentthrough the second leg 3612 when the pyro-fuse 3620 activates (e.g.,where contactor 3626 dynamics may be slower than the pyro-fuse 3620dynamics). An example includes a resistor 3624 coupled in a seriesarrangement with the pyro-fuse 3620, such that a resulting currentthrough the first leg 3610 after the thermal fuse 3622 activates isbelow a second threshold current flow value—for example to reduce thecurrent through the motive electrical power path 3604 if the thermalfuse 3622 activates when the pyro-fuse 3620 has not already activated(e.g., an unmeasured current spike, and/or a current spike occurringafter a controller has failed and is unable to command the pyro-fuse3620 to open). An example system includes a second thermal fuse (notshown) coupled in a series arrangement with the pyro-fuse 3620, suchthat a resulting current through the first leg 3610 after the thermalfuse 3622 activates is sufficient to activate the second thermal fuse.For example, the use of a second thermal fuse provides for all branchesof the motive electrical power path 3604 to have fuses with physicalresponses present, avoiding failures due to loss of ability to detectcurrents in the system or to command a pyro-fuse 3620 to activate. Inthe example, the sizing of the thermal fuse 3622 and the second thermalfuse can be made to avoid thermal wear during normal operations, butsufficient such that either thermal fuse 3622 will readily protect thesystem when the other leg (the first leg 3610 or second leg 3612) isopened during high current events. It can be seen that embodiments ofthe system depicted in FIG. 36 provide for both the high controllabilityof a pyro-fuse 3620 to disconnect the power, along with the robustprotection of a thermal fuse that will physically respond to highcurrent values regardless of failures in current sensing or controlleroperation, as may occur during a system failure, vehicle accident, etc.Additionally, the utilization of the two legs 3610, 3612, includingpotentially current management therethrough with resistor(s) 3624 and/orcontactor(s) 3626, allows for the utilization of fuses that can be sizedto avoid thermal wear and/or nuisance failures over the life of thevehicle, while still providing for reliable power disconnection for highcurrent events.

Referencing FIG. 37, an example procedure includes an operation 3702 todetermine a current flow through a motive electrical power path of avehicle; an operation 3704 to direct the current flow through a currentprotection circuit having a parallel arrangement, with a pyro-fuse on afirst leg of the current protection circuit and a thermal fuse on asecond leg of the current protection circuit; and an operation 3706 toprovide a pyro-fuse activation command in response to the current flowexceeding a threshold current flow value.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation to configure a firstresistance through the first leg and a second resistance through thesecond leg such that a resulting current through the second leg afterthe pyro-fuse activates is sufficient to activate the thermal fuse. Anexample procedure includes an operation to configure a second resistancethrough the second leg such that a resulting current through the secondleg after the pyro-fuse activates is below a second threshold currentflow value. An example procedure includes an operation to a contactorcoupled in a series arrangement with the thermal fuse, the procedurefurther including providing a contactor open command in response to atleast one of providing the pyro-fuse activation command or the currentflow exceeding the threshold current flow value; and/or an operation toconfigure a second resistance through the second leg such that aresulting current through the second leg after the pyro-fuse activatesis below a second threshold current flow value. An example procedurefurther including a resistor coupled in a series arrangement with thepyro-fuse such that a resulting current through the first leg after thethermal fuse activates is below a second threshold current flow value;and/or further including a second thermal fuse coupled in a seriesarrangement with the pyro-fuse, such that a resulting current throughthe first leg after the thermal fuse activates is sufficient to activatethe second thermal fuse.

Referencing FIG. 38, an example system includes a vehicle 3802 having amotive electrical power path 3804; a power distribution unit 3806 havinga current protection circuit 3808 disposed in the motive electricalpower path 3804, where the current protection circuit includes a firstleg 3810 of the including a thermal fuse 3820 and a second leg 3812including a contactor 3822. The first leg 3810 and the second leg 3812are coupled in a parallel arrangement. The system includes a controller3614 having a current detection circuit 3816 structured to determine acurrent flow through the motive electrical power path 3804; and a fusemanagement circuit 3818 structured to provide a contactor activationcommand in response to the current flow. The contactor 3822 isresponsive to the contactor activation command.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes where the contactor 3822 is open during nominaloperations of the vehicle, and where the fuse management circuit isstructured to provide the contactor activation command as a contactorclosing command in response to determining that the current flow is aabove a thermal wear current for the thermal fuse 3820; and/or where thefuse management circuit is further structured to provide the contactoractivation command as the contactor closing command in response todetermining that the current flow is below a current protection valuefor the motive electrical power path 3804. An example system includeswhere the contactor 3822 is closed during nominal operations of thevehicle, and where the fuse management circuit is structured to providethe contactor activation command as a contactor opening command inresponse to determining that the current flow is above a currentprotection value for the motive electrical power path 3804. An examplesystem includes where the fuse management circuit is further structuredto provide the contactor activation command in response to the currentflow by performing at least one operation selected from the operationsconsisting of: responding to a rate of change of the current flow;responding to a comparison of the current flow to a threshold value;responding to one of an integrated or accumulated value of the currentflow; and responding to one of an expected or a predicted value of anyof the foregoing. It can be seen that the embodiments of the systemdepicted in FIG. 38 allow for the utilization of an oversized fuse 3820that will experience reduced wear and increased life, while stillallowing for circuit protection for moderate overcurrent (e.g.,utilizing the contactor) and fused protection for high overcurrentvalues. It can be seen that the embodiments of the system depicted FIG.38 allow for utilization of a nominally sized or undersized fuse 3820that can reliably open the circuit at moderate overcurrent values, butexperience reduced wear and increased life (e.g., by sharing currentthrough the contactor branch).

Referencing FIG. 39, an example procedure includes an operation 3902 todetermine a current flow through a motive electrical power path of avehicle; an operation 3904 to direct the current flow through a currentprotection circuit having a parallel arrangement, with a thermal fuse ona first leg of the current protection circuit and a contactor on asecond leg of the current protection circuit; and an operation 3906 toprovide a contactor activation command in response to the current flow.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation to close the contactorin response to the current flow. An example procedure includes anoperation to determine that the current flow is below a currentprotection value for the motive electrical power path before the closingthe contactor. An example procedure includes at least one operationselected from the operations consisting of: responding to a rate ofchange of the current flow; responding to a comparison of the currentflow to a threshold value; responding to one of an integrated oraccumulated value of the current flow; and responding to one of anexpected or a predicted value of any of the foregoing. An exampleprocedure includes an operation to open the contactor in response to thecurrent flow; an operation to determine that the current flow is above acurrent protection value for the motive electrical power path beforeopening the contactor; and/or an operation to open the contactorincluding performing any one or more of: responding to a rate of changeof the current flow; responding to a comparison of the current flow to athreshold value; responding to one of an integrated or accumulated valueof the current flow; and responding to one of an expected or a predictedvalue of any of the foregoing.

Referencing FIG. 40, an example system includes a vehicle 4002 having amotive electrical power path 4004; a power distribution unit 4006 havinga current protection circuit 4008 disposed in the motive electricalpower path 4004, where the current protection circuit includes a firstleg 4010 of the current protection circuit 4008 including a thermal fuse4020 and a second leg 4012 of the current protection circuit 4008including a solid state switch 4022. The first leg 4010 and the secondleg 4012 are coupled in a parallel arrangement. The example systemincludes a controller 4014 including a current detection circuit 4016structured to determine a current flow through the motive electricalpower path 4004 and a fuse management circuit 4018 structured to providea switch activation command in response to the current flow. The solidstate switch 4022 is responsive to the switch activation command. Incertain embodiments, the system includes a contactor 4024 coupled to thecurrent protection circuit 4008, where the contactor 4024 in the openposition disconnects the current protection circuit 4008 (e.g., thecontactor 4024 in series with both legs 4010, 4012), and/or thecontactor 4024 in series with the solid state switch 4022 on the secondleg 4012). Any contactor described throughout the present disclosuremay, in certain embodiments, be a solid state switch instead of, or inseries with, a conventional contactor device. Solid state switches areknown to have rapid response and are robust to opening during highcurrent events. However, solid state switches also experience a smallleakage current, which may be acceptable in certain embodiments, or notacceptable in other embodiments. In certain embodiments, the utilizationof a conventional contactor with a solid state switch allows for therapid response time and survivability of the solid state switch, as wellas the enforced zero current of a conventional contactor. In certainembodiments, the solid state switch is utilized to open the circuitfirst, and then the conventional contactor opens the circuit second,allowing for the avoidance of conditions where the conventionalcontactor opens under high current conditions.

Referencing FIG. 41, an example procedure includes an operation 4102 todetermine a current flow through a motive electrical power path of avehicle; an operation 4104 to direct the current flow through a currentprotection circuit having a parallel arrangement, with a thermal fuse ona first leg of the current protection circuit and a solid state switchon a second leg of the current protection circuit; and an operation 4106to provide a switch activation command in response to the current flow.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation to close the solid stateswitch in response to the current flow; and/or determine that thecurrent flow is below a current protection value for the motiveelectrical power path before the closing the solid state switch. Forexample, a current flow value or transient may be sufficiently high tocause degradation of the thermal fuse, but lower than a threshold wherea system protection response from the thermal fuse is required. Incertain embodiments, closing the solid state switch reduces the currentflow and/or transient through the thermal fuse, reducing the wear and/ora nuisance failure of the thermal fuse. An example procedure includes anoperation to close the solid state switch includes performing at leastone operation such as: responding to a rate of change of the currentflow; responding to a comparison of the current flow to a thresholdvalue; responding to one of an integrated or accumulated value of thecurrent flow; and responding to one of an expected or a predicted valueof any of the foregoing. An example procedure includes an operation toopen the solid state switch in response to the current flow; and/ordetermine that the current flow is above a current protection value forthe motive electrical power path before opening the solid state switch.An example procedure includes an operation to open the solid stateswitch includes performing at least one operation selected from theoperations consisting of: responding to a rate of change of the currentflow; responding to a comparison of the current flow to a thresholdvalue; responding to one of an integrated or accumulated value of thecurrent flow; and responding to one of an expected or a predicted valueof any of the foregoing. An example procedure includes an operation toopen a contactor after the opening the solid state switch, where openingthe contactor disconnects one of the current protection circuit or thesecond leg of the current protection circuit.

Referencing FIG. 42, an example system includes a vehicle having amotive electrical power path 4204; a power distribution unit 4206 havinga current protection circuit 4208 disposed in the motive electricalpower path 4204, where the current protection circuit includes a firstleg 4220 of the current protection circuit 4208 including a firstthermal fuse 4220, a second leg 4212 of the current protection circuit4208 including a second thermal fuse 4222 and a contactor 4224, andwhere the first leg 4220 and the second leg 4212 are coupled in aparallel arrangement. The example system includes a controller,including: a current detection circuit 4216 structured to determine acurrent flow through the motive electrical power path 4204; and a fusemanagement circuit 4218 structured to provide a contactor activationcommand in response to the current flow. The contactor 4224 isresponsive to the contactor activation command.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes where the contactor 4224 is open during nominaloperations of the vehicle, and where the fuse management circuit 4218 isstructured to provide the contactor activation command as a contactorclosing command in response to determining that the current flow is aabove a thermal wear current for the first thermal fuse 4220. An examplesystem includes the fuse management circuit 4218 further structured toprovide the contactor activation command as a contactor closing commandin response to determining that the current flow is below a currentprotection value for the motive electrical power path 4204. An examplesystem includes a vehicle operating condition circuit 4226 structured todetermine an operating mode for the vehicle (e.g., moving, stopped, highperformance, high economy, charging, quick charging, etc.), and wherethe fuse management circuit 4218 is further structured to provide thecontactor activation command in response to the operating mode. Anexample system includes the fuse management circuit 4218 furtherstructured to provide the contactor activation command as a contactorclosing command in response to the operating mode including at least oneoperating mode selected from the operating modes consisting of: acharging mode; a quick charging mode; a high performance mode; a highpower request mode; an emergency operation mode; and/or a limp homemode. An example system includes where the contactor 4224 is closedduring nominal operations of the vehicle, and where the fuse managementcircuit 4218 is structured to provide the contactor activation commandas a contactor opening command in response to determining that thecurrent flow is above a current protection value for the motiveelectrical power path 4204. An example system includes where thecontactor is closed during nominal operations of the vehicle, and wherethe fuse management circuit 4218 is structured to provide the contactoractivation command as a contactor opening command in response to theoperating mode; and/or where the fuse management circuit 4218 is furtherstructured to provide the contactor activation command as a contactoropening command in response to the operating mode including at least oneof an economy mode or a service mode. For example, during certainoperating conditions such as an economy mode or during a service event,a reduced maximum power throughput through the motive electrical powerpath 4204 may be enforced, where the opening of the contactor 4224 isutilized to provide configured fuse protection for the reduced maximumpower throughput.

Referencing FIG. 43, an example procedure includes an operation 4302 todetermine a current flow through a motive electrical power path of avehicle; an operation 4304 to direct the current flow through a currentprotection circuit having a parallel arrangement, with a first thermalfuse on a first leg of the current protection circuit and a secondthermal fuse and a contactor on a second leg of the current protectioncircuit; and an operation 4306 to provide a contactor activation commandin response to the current flow.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation to close the contactorin response to the current flow being above a thermal wear current forthe first thermal fuse; and/or closing the contactor further in responseto the current flow being below a current protection value for themotive electrical power path. An example procedure includes an operationto determine an operating mode for the vehicle, and providing thecontactor activation command further in response to the operating mode.An example procedure includes an operation to provide the contactoractivation command as a contactor closing command in response to theoperating mode including at least one operating mode selected from theoperating modes consisting of: a charging mode; a high performance mode;a high power request mode; an emergency operation mode; and a limp homemode. An example procedure includes an operation to provide thecontactor activation command as a contactor opening command in responseto determining that the current flow is above a current protection valuefor the motive electrical power path; and/or provide the contactoractivation command as a contactor opening command in response to theoperating mode including at least one of an economy mode or a servicemode.

Referencing FIG. 44, an example system includes a vehicle 4402 having amotive electrical power path 4404; a power distribution unit 4406 havinga current protection circuit 4408 disposed in the motive electricalpower path 4404, where the current protection circuit includes: a firstleg 4410 of the current protection circuit 4408 including a firstthermal fuse 4420 and a first contactor 4424; a second leg 4412 of thecurrent protection circuit 4408 including a second thermal fuse 4422 anda second contactor 4426; and where the first leg 4410 and the second leg4412 are coupled in a parallel arrangement. The example system includesa controller 4414 including a current detection circuit 4416 structuredto determine a current flow through the motive electrical power path4404; and a fuse management circuit 4418 structured to provide aplurality of contactor activation commands in response to the currentflow. The first contactor 4424 and the second contactor 4426 areresponsive to the contactor activation commands, thereby providing aselected configuration of the current protection circuit 4408.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes where the current protection circuit furtherincludes: one or more additional legs 4413, where each additional leg4413 includes an additional thermal fuse 4423 and an additionalcontactor 4428; and where each additional contactor 4428 is furtherresponsive to the contactor activation commands, thereby providing theselected configuration of the current protection circuit 4408. Anexample system includes a vehicle operating condition circuit 4430structured to determine an operating mode for the vehicle, and where thefuse management circuit 4418 is further structured to provide thecontactor activation commands in response to the operating mode. Anexample fuse management circuit 4418 is further structured to determinean active current rating for the motive electrical power path 4404 inresponse to the operating mode, and to provide the contactor activationcommands in response to the active current rating. An example systemincludes where the first leg 4410 of the current protection circuit 4408further includes an additional first contactor 4427 in a parallelarrangement with the first thermal fuse 4420, where the currentdetection circuit 4416 is further structured to determine a first legcurrent flow, where the fuse management circuit 4418 is furtherstructured to provide the contactor activation commands further inresponse to the first leg current flow, and where the additional firstcontactor 4427 is responsive to the contactor activation commands. Anexample system includes the additional first contactor 4427 being openduring nominal operations of the vehicle, and where the fuse managementcircuit 4418 is structured to provide the contactor activation commandsincluding an additional first contactor closing command in response todetermining that the first leg current flow is a above a thermal wearcurrent for the first thermal fuse 4420. An example system includes thefuse management circuit 4418 structured to provide the additional firstcontactor closing command in response to determining at least one of:that the first leg current flow is below a first leg current protectionvalue, or that the current flow is below a motive electrical power pathcurrent protection value. An example system includes where theadditional first contactor 4427 is closed during nominal operations ofthe vehicle, and where the fuse management circuit 4418 is structured toprovide the contactor activation commands including an additional firstcontactor opening command in response to determining at least one of:that the first leg current flow is above a first leg current protectionvalue, or that the current flow is above a motive electrical power pathcurrent protection value. The example system may further includeadditional contactors 4428 positioned on any one or more of the legs4410, 4412, 4413. Any one or more of the contactors 4424, 4426, 4428 maybe configured in series and/or parallel with the associated thermal fuse4420, 4422, 4423 on the associated leg.

Referencing FIG. 45, an example procedure includes an operation 4502 todetermine a current flow through a motive electrical power path of avehicle; an operation 4504 to direct the current flow through a currentprotection circuit having a parallel arrangement, with a first thermalfuse and a first contactor on a first leg of the current protectioncircuit, and a second thermal fuse and a second contactor on a secondleg of the current protection circuit; and an operation 4506 to providea selected configuration of the current protection circuit in responseto the current flow through the motive electrical power path of thevehicle, where providing the selected configuration includes providing acontactor activation command to each of the first contactor and thesecond contactor.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure includes an operation further including at least oneadditional leg of the current protection circuit, each additional leg ofthe current protection circuit having an additional thermal fuse and anadditional contactor, and where the providing the selected configurationof the current protection circuit includes providing a contactoractivation command to each additional contactor. An example procedureincludes an operation to determine an operating mode for the vehicle,and providing the selected configuration further in response to theoperating mode; and/or an operation to determine an active currentrating for the motive electrical power path in response to the operatingmode, and where providing the selected configuration of the currentprotection circuit is further in response to the active current rating.An example procedure includes an operation to determine an activecurrent rating for the motive electrical power path, and where providingthe selected configuration of the current protection circuit is furtherin response to the active current rating. An example procedure includesan operation where the first leg of the current protection circuitfurther includes an additional first contactor in a parallel arrangementwith the first thermal fuse, the procedure further including:determining a first leg current flow, and where providing the selectedconfiguration further includes providing a contactor activation commandto the additional first contactor; an operation to close the additionalfirst contactor in response to determining that the first leg currentflow is a above a thermal wear current for the first thermal fuse; anoperation to close the additional first contactor further in response todetermining at least one of: that the first leg current flow is below afirst leg current protection value, or that the current flow is below amotive electrical power path current protection value; and/or anoperation to open the additional first contactor in response todetermining at least one of: that the first leg current flow is above afirst leg current protection value, or that the current flow is above amotive electrical power path current protection value.

Referencing FIG. 46, an example system includes a vehicle 4602 having amotive electrical power path 4604; a power distribution unit 4606 havinga current protection circuit 4608 disposed in the motive electricalpower path 4604, where the current protection circuit 4608 includes afuse 4610. The example system further includes a controller 4614including a fuse status circuit 4616 structured to determine a fuseevent value; and a fuse management circuit 4618 structured to provide afuse event response based on the fuse event value.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes a fuse life description circuit 4619 structuredto determine a fuse life remaining value, where the fuse event valueincludes a representation that the fuse life remaining value is below athreshold value, and where the fuse management circuit 4618 is furtherstructured to provide the fuse event response further based on the fuselife remaining value. Example and non-limiting operations to provide thefuse event include providing a fault code and/or a notification of thefuse event value, for example to a datalink, another controller in thesystem, as a service notification, to a fleet owner (e.g., a maintenancemanager), stored as a fault code for service access, and/or as anotification to an operator, a mobile device, a service report, or thelike. Example and non-limiting operations to provide the fuse eventresponse include: adjusting a maximum power rating for the motiveelectrical power path; adjusting a maximum power slew rate for themotive electrical power path; and/or adjusting a configuration of thecurrent protection circuit. An example system includes where the currentprotection circuit 4606 further includes a contactor 4612 coupled in aparallel arrangement to the fuse 4610; and/or where the fuse managementcircuit 4618 is further structured to provide a contactor activationcommand in response to the fuse event value. In the example, thecontactor 4612 is responsive to the contactor activation command. Anexample system includes where the fuse management circuit 4618 isfurther structured to provide the contactor activation command as acontactor closing command in response to the fuse event value being oneof a thermal wear event or an imminent thermal wear event for the fuse4610. An example system includes where the fuse management circuit 4618is further structured to adjust a current threshold value for thecontactor activation command in response to the fuse life remainingvalue (e.g., open the contactor at a lower or higher threshold as thefuse ages). An example system includes a cooling system 4620 at leastselectively thermally coupled to the fuse, and a cooling systeminterface 4622 (e.g., hardware interfaces such as flow couplings,valves, etc., and/or communication interfaces such as network commands,electrical couplings, etc.); and/or where providing the fuse eventresponse includes adjusting a cooling system interface 4622 for thecooling system 4620 in response to the fuse life remaining value (e.g.,increasing active cooling capability to the fuse as the fuse ages).

Referencing FIG. 47, an example procedure includes an operation 4702 todetermine a fuse event value for a fuse disposed in a current protectioncircuit, the current protection circuit disposed in a motive electricalpower path of a vehicle; and an operation 4704 to provide a fuse eventresponse based on the fuse event value.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation to determine a fuse liferemaining value, where the fuse event value includes a representationthat the fuse life remaining value is below a threshold value, andproviding the fuse event response further based on the fuse liferemaining value; an operation to provide the fuse event responseincludes providing at least one of a fault code or a notification of thefuse event value; an operation to provide the fuse event responseincludes adjusting a maximum power rating for the motive electricalpower path; an operation to provide the fuse event response includesadjusting a maximum power slew rate for the motive electrical powerpath; an operation to provide the fuse event response includes adjustinga configuration of the current protection circuit. An example procedureincludes an operation where the current protection circuit furtherincludes a contactor coupled in a parallel arrangement to the fuse;where the fuse management circuit is further structured to provide acontactor activation command in response to the fuse event value; andwhere the contactor is responsive to the contactor activation command;where the fuse management circuit is further structured to provide thecontactor activation command as a contactor closing command in responseto the fuse event value including one of a thermal wear event or animminent thermal wear event for the fuse; and/or where the fusemanagement circuit is further structured to adjust a current thresholdvalue for the contactor activation command in response to the fuse liferemaining value. An example procedure includes an operation to providethe fuse event response includes adjusting a cooling system interfacefor a cooling system at least selectively thermally coupled to the fusein response to the fuse life remaining value. An example procedureincludes an operation to provide the fuse event response includesproviding at least one of a fault code or a notification of the fuseevent value. An example procedure includes an operation to determine anaccumulated fuse event description in response to the fuse eventresponse, and storing the accumulated fuse event description. An exampleprocedure includes an operation to provide the accumulated fuse eventdescription, where providing the accumulated fuse event descriptionincludes at least one of providing at least one of a fault code or anotification of the accumulated fuse event description; and an operationto provide the accumulated fuse event description in response to atleast one of a service event or a request for the accumulated fuse eventdescription.

Referencing FIG. 48, an example system includes a vehicle 4802 having amotive electrical power path 4804 and at least one auxiliary electricalpower path 4805; a power distribution unit 4806 having a motive currentprotection circuit 4808 disposed in the motive electrical power path4804, the motive current protection circuit including a fuse; and anauxiliary current protection circuit 4810 disposed in each of the atleast one auxiliary electrical power paths 4805, each auxiliary currentprotection circuit 4810 including an auxiliary fuse (not shown). Thesystem includes a controller 4814 including: a current determinationcircuit 4816 structured to interpret a motive current valuecorresponding to the motive electrical power path, and an auxiliarycurrent value corresponding to each of the at least one auxiliaryelectrical power paths.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes a motive current sensor 4824 electricallycoupled to the motive electrical power path 4804, where the motivecurrent sensor 4824 is configured to provide the motive current value.An example system includes at least one auxiliary current sensor 4826each electrically coupled to one of the at least one auxiliaryelectrical power paths, each auxiliary current sensor 4826 configured toprovide the corresponding auxiliary current value. An example systemincludes where the controller 4814 further includes a vehicle interfacecircuit 4828, the vehicle interface circuit structured to provide themotive current value to a vehicle network (not shown); where the vehicleinterface circuit 4828 is further structured to provide the auxiliarycurrent value corresponding to each of the at least one auxiliaryelectrical power paths 4805 to the vehicle network; and/or furtherincluding a battery management controller (not shown) configured toreceive the motive current value from the vehicle network. In certainembodiments, one or more of the motive current value and/or theauxiliary current value(s) are provided by a fuse current model, forexample determined in accordance with a load voltage drop across thefuse and/or a fuse resistance (and/or fuse dynamic resistance or fuseimpedance) value determined from an injected current operation acrossthe fuse. The utilization of a fuse current model can provide for higheraccuracy (e.g. relative to a moderately capable or inexpensive currentsensor) and/or faster response time for current determination than asensor. In certain embodiments, a current sensor may be combined withthe utilization of a fuse current model, for example favoring one or theother of the sensor or the model depending upon the operatingconditions, and the expected accuracies of the sensor or the model inview of the operating conditions.

Referencing FIG. 49, an example procedure includes an operation 4902 toprovide a power distribution unit having a motive current protectioncircuit and at least one auxiliary current protection circuit; anoperation 4904 to power a vehicle motive electrical power path throughthe motive current protection circuit; an operation 4906 to power atleast one auxiliary load through a corresponding one of the at least oneauxiliary current protection circuit; an operation 4908 to determine amotive current value corresponding to the motive electrical power path;and an operation 4910 to determine an auxiliary current valuecorresponding to each of the at least one auxiliary current protectioncircuits.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation to provide the motivecurrent value to a vehicle network; and/or an operation to receive themotive current value with a battery management controller.

Referencing FIG. 50, an example system includes a vehicle 5002 having amotive electrical power path 5004; a power distribution unit 5006 havinga current protection circuit 5008 disposed in the motive electricalpower path 5004, where the current protection circuit includes: athermal fuse 5020; and a contactor 5022 in a series arrangement with thethermal fuse 5020. The system further includes a controller 5014,including: a current detection circuit 5016 structured to determine acurrent flow through the motive electrical power path 5004; and a fusemanagement circuit 5018 structured to provide a contactor activationcommand in response to the current flow; and where the contactor 5022 isresponsive to the contactor activation command.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes where the thermal fuse 5020 includes a currentrating that is higher than a current corresponding to a maximum powerthroughput of the motive electrical power path 5004 (e.g., where thefuse is sized to avoid wear or degradation up to the maximum powerthroughput, where the fuse is sized to accommodate a higher power ratingand/or a quick charging power throughput, etc.). An example systemincludes where the thermal fuse 5020 includes a current rating that ishigher than a current corresponding to a quick charging power throughputof the motive electrical power path 5004. An example system includeswhere the contactor 5020 includes a current rating that is higher than acurrent corresponding to a maximum power throughput of the motiveelectrical power path 5004. In certain embodiments, the currentcorresponding to the maximum power throughput of the motive electricalpower path 5004 may correspond to a current at nominal voltage, and/or acurrent at a degraded and/or failure mode voltage (e.g., as the batterypack ages, and/or if one or more cells are deactivated). An examplesystem includes where the contactor 5022 includes a current rating thatis higher than a current corresponding to a quick charging powerthroughput of the motive electrical power path 5004. An example systemincludes where the fuse management circuit 5018 is further structured toprovide the contactor activation command as a contactor opening commandin response to the current flow indicating a motive electrical powerpath protection event. An example current detection circuit 5016determines the motive electrical power path protection event byperforming at least one operation such as: responding to a rate ofchange of the current flow; responding to a comparison of the currentflow to a threshold value; responding to one of an integrated oraccumulated value of the current flow; and/or responding to one of anexpected or a predicted value of any of the foregoing.

Referencing FIG. 51, an example procedure includes an operation 5102 topower a motive electrical power path of a vehicle through a currentprotection circuit including a thermal fuse and a contactor in a seriesarrangement with the thermal fuse; and an operation 5104 to determine acurrent flow through the motive electrical power path; and an operationto selectively open the contactor in response to the current flow.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation to provide the thermalfuse having a current rating that is higher than a current correspondingto a maximum power throughput of the motive electrical power path. Anexample procedure includes an operation to provide the thermal fusehaving a current rating that is higher than a current corresponding to aquick charging power throughput of the motive electrical power path. Anexample procedure includes an operation to provide the contactor havinga current rating that is higher than a current corresponding to amaximum power throughput of the motive electrical power path. An exampleprocedure includes an operation to provide the contactor having acurrent rating that is higher than a current corresponding to a quickcharging power throughput of the motive electrical power path. Anexample procedure includes an operation to open the contactor is furtherin response to at least one of: a rate of change of the current flow; acomparison of the current flow to a threshold value; one of anintegrated or accumulated value of the current flow; and/or an expectedor predicted value of any of the foregoing.

Referencing FIG. 52, an example procedure includes an operation 5202 topower a motive electrical power path of a vehicle through a currentprotection circuit including a thermal fuse and a contactor in a seriesarrangement with the thermal fuse; an operation 5204 to determine acurrent flow through the motive electrical power path; an operation 5206to open the contactor in response to the current flow exceeding athreshold value; an operation 5208 to confirm that vehicle operatingconditions allow for a re-connection of the contactor; and an operation5210 to command the contactor to close in response to the vehicleoperating conditions. Previously known fused system, including systemshaving a controllable pyro-fuse, are not capable of restoring systempower after an overcurrent event, as the fuse has opened the circuit andcannot be restored. Certain example embodiments throughout the presentdisclosure provide for a system that can open the circuit withoutactivation of the fuse under certain circumstances. Accordingly, incertain embodiments, power can be restored after a high current event,providing for additional capability. However, in certain embodiments, itmay be undesirable to restore power to the system, for example if thesystem is being accessed by emergency personnel and/or service after theovercurrent event. In certain embodiments, the controller is configuredto perform certain checks, including checking current operatingconditions and permissions, before attempting to restore power.Additionally or alternatively, the controller is configured todetermine, during the attempted restoration of power and/or shortlythereafter, whether a condition causing an overcurrent event is stillpresent. Additionally or alternatively, the controller is configured todetermine whether the contactor or another electrical device has beendamaged during the overcurrent event, or during the disconnectionprocess being performed to halt the overcurrent event.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation to confirm the vehicleoperating conditions, and in certain embodiments further includesdetermining at least one vehicle operating condition such as: anemergency vehicle operating condition; a user override vehicle operatingcondition; a service event vehicle operating condition; and are-connection command communicated on a vehicle network. In certainembodiments, an emergency vehicle operating condition may indicate thata reconnection is desirable—for example where continued operation of thevehicle is more important than damage to the electrical system of thevehicle. In certain embodiments, an emergency vehicle operatingcondition may indicate that a reconnection is undesirable—for examplewhere the vehicle has experienced an accident, and disconnection ofpower is desired to protect vehicle occupants and/or emergency responsepersonnel. In certain embodiments, a service event vehicle operatingcondition indicates that a reconnection is desirable—for example where aservicing operator is requesting re-powering of the vehicle. In certainembodiments, a service event vehicle operating condition indicates thata reconnection is undesirable—for example when service personnel areperforming service, maintenance, or repairs on the vehicle.

An example procedure includes an operation to monitor the motiveelectrical power path during the commanding the contactor to close, andre-opening the contactor in response to the monitoring (e.g., where thepost-closing current and/or a current transient indicates that acondition causing the overcurrent may still be active). An exampleprocedure includes an operation to determine an accumulated contactoropen event description in response to the opening the contactor, and/oran operation to prevent the commanding the contactor to close inresponse to the accumulated contactor open event description exceeding athreshold value. For example, the accumulated contactor open event maybe determined from a number of contactor open events under load, and/oraccording to a severity of those events. Where a number of open eventsunder load are experienced, and/or where one or more severe open eventsare experienced, re-connection of the contactor may be undesirable toavoid the risk of further damage, overheating of the contactor, and/orsticking or welding of a damaged contactor that may prevent a subsequentre-opening of the contactor. An example procedure includes an operationto adjust the accumulated contactor open event description in responseto the current flow during the opening of the contactor. An exampleprocedure includes an operation to diagnose a welded contactor inresponse to one of the current flow during the opening the contactor,and/or a monitoring of the motive electrical power path during thecommanding the contactor to close. An example procedure includes anoperation to diagnose a welded contactor in response to a monitoring ofat least one of a contactor actuator position (e.g., a failure of theactuator to respond as expected on command), a contactor actuatorresponse, and/or the motive electrical power path during the opening thecontactor. An example procedure further includes an operation to preventthe commanding the contactor to close in response to the diagnosedwelded contactor.

Referencing FIG. 53, an example apparatus includes a motive electricalpower current protection circuit 5308 structured to: determine a currentflow through a motive electrical power path 5304 of a vehicle; and opena contactor 5322 disposed in the current protection circuit 5308including a thermal fuse 5320 and the contactor 5322 in a seriesarrangement with the thermal fuse 5320 in response to the current flowexceeding a threshold value. The apparatus further includes a vehiclere-power circuit 5316 structured to: confirm that vehicle operatingconditions allow for a re-connection of the contactor; and to close thecontactor 5322 in response to the vehicle operating conditions.

Certain further aspects of an example apparatus are described following,any one or more of which may be present in certain embodiments. Anexample apparatus includes where the vehicle re-power circuit 5316 isfurther structured to confirm the vehicle operating conditions byconfirming at least one vehicle operating condition such as: anemergency vehicle operating condition; a user override vehicle operatingcondition; a service event vehicle operating condition; and are-connection command communicated on a vehicle network (not shown). Forexample, a system may include an operator override interface (e.g., abutton, a sequence of control inputs, or the like) that provide an inputfor the operator to request continued power operations where the motiveelectrical power current protection circuit 5308 has opened thecontactor 5322 to protect the motive power system. In certainembodiments, operator access to the override is utilized by the vehiclere-power circuit 5316 to command a re-connection of the contactor. Incertain embodiments, the re-connection by an operator input includesonly allowing a re-connection for certain applications (e.g., anemergency or military vehicle), and/or only allowing a re-connection fora period of time (e.g., 10 seconds or 30 seconds), and/or only allowinga re-connection when the electrical conditions after the re-connectiondo not indicate that another overcurrent event is occurring. In certainembodiments, the vehicle re-power circuit 5316 additionally oralternatively may de-rate maximum power, de-rate the maximum power slewrate, provide a notification or warning to the operator duringre-connection operations, and/or provide a notification or warning tothe operator when a re-connection time period is about to expire (e.g.,a first light or light sequence during re-connection operations, and adifferent light or light sequence when the re-connection time period isabout to expire).

An example apparatus includes where the motive electrical power currentprotection circuit 5308 is further structured to monitor the motiveelectrical power path during the closing the contactor to close, andwhere the vehicle re-power circuit 5316 is further structured to re-openthe contactor in response to the monitoring. An example apparatusincludes a contactor status circuit 5318 structured to determine anaccumulated contactor open event description in response to the openingthe contactor 5322; where the vehicle re-power circuit 5316 is furtherstructured to prevent the closing the contactor 5322 in response to theaccumulated contactor open event description exceeding a thresholdvalue; and/or where the contactor status circuit 5318 is furtherstructured to adjust the accumulated contactor open event description inresponse to the current flow during the opening the contactor. Anexample apparatus includes a contactor status circuit 5318 structured todiagnose a welded contactor in response to one of, during the commandingthe contactor to close: the current flow during the opening thecontactor 5322, and/or a monitoring of the motive electrical power pathby the motive electrical power current protection circuit 5308. Anexample apparatus includes a contactor status circuit 5318 structured todiagnose a welded contactor in response to a monitoring of, during theopening of the contactor, at least one of: a contactor actuator positionby the vehicle re-power circuit 5316; a contactor actuator response bythe vehicle re-power circuit 5316; and the motive electrical power pathby the motive electrical power current protection circuit 5308; and/orwhere the contactor status circuit 5318 is further structured to preventthe closing the contactor in response to the diagnosed welded contactor.

An example system (e.g., referencing FIGS. 1 and 2) includes a vehiclehaving a motive electrical power path; a power distribution unitincluding: a current protection circuit disposed in the motiveelectrical power path, the current protection circuit including athermal fuse and a contactor in a series arrangement with the thermalfuse; a high voltage power input coupling including a first electricalinterface for a high voltage power source; a high voltage power outputcoupling including a second electrical interface for a motive powerload; and where the current protection circuit electrically couples thehigh voltage power input to the high voltage power output, and where thecurrent protection circuit is at least partially disposed in a laminatedlayer (e.g., referencing FIGS. 12 through 17) of the power distributionunit, where the laminated layer includes an electrically conductive flowpath disposed between two electrically insulating layers.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes where current protection circuit includes amotive power bus bar disposed in the laminated layer of the powerdistribution unit. An example system includes where the vehicle furtherincludes an auxiliary electrical power path; where the powerdistribution unit further includes: an auxiliary current protectioncircuit disposed in the auxiliary electrical power path, the auxiliarycurrent protection circuit including a second thermal fuse; an auxiliaryvoltage power input coupling including a first auxiliary electricalinterface for a low voltage power source; an auxiliary voltage poweroutput coupling including a second auxiliary electrical interface for aan auxiliary load; and where the auxiliary current protection circuitelectrically couples the auxiliary voltage power input to the auxiliaryvoltage power output, and where the auxiliary current protection circuitis at least partially disposed in the laminated layer of the powerdistribution unit. An example system includes where the laminated layerof the power distribution unit further includes at least one thermallyconductive flow path disposed between two thermally insulating layers;where the at least one thermally conductive flow path is configured toprovide thermal coupling between a heat sink (e.g., a cooling system, ahousing or other system aspect having a high thermal mass, and/orambient air), and a heat source, where the heat source includes at leastone of the contactor, the thermal fuse, and the second thermal fuse;where the heat sink includes at least one of a thermal coupling to anactive cooling source and a housing of the power distribution unit;and/or further including a thermal conduit disposed between the at leastone thermally conductive flow path and the heat source.

Referencing FIG. 55, an example system includes a vehicle 5502 having amotive electrical power path 5504; a power distribution unit 5506including a current protection circuit 5508 disposed in the motiveelectrical power path 5504, the current protection circuit 5508including a thermal fuse 5520 and a contactor 5522 in a seriesarrangement with the thermal fuse 5520; a current source circuit 5516electrically coupled to the thermal fuse 5520 and structured to inject acurrent across the thermal fuse 5520 (e.g., using an op-amp drivencurrent source); and a voltage determination circuit 5518 electricallycoupled to the thermal fuse 5520 and structured to determine at leastone of an injected voltage amount and a thermal fuse impedance value.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes where the motive electrical power path 5504includes a direct current power path (e.g., the motive power path);where the current source circuit 5516 includes at least one of analternating current source and a time varying current source, andfurther including a hardware filter 5524 electrically coupled to thethermal fuse 5520. In the example, the hardware filter 5524 isconfigured in response to an injection frequency of the current sourcecircuit 5516; where the hardware filter 5524 includes a high pass filter5526 having a cutoff frequency determined in response to the injectionfrequency of the current source circuit 5516 (e.g., to remove voltagefluctuations that are significantly lower than the injection ACfrequency). An example system includes the hardware filter 5524 having alow pass filter 5528 having a cutoff frequency determined in response toat least one of the injection frequency of the current source circuit(e.g., to remove voltage fluctuations induced by the current injection)or a load change value of the motive electrical power path 5504 (e.g.,to remove transient fluctuations caused by a change in the load). Incertain embodiments, the high pass filtered voltage is analyzedseparately from the low pass filtered voltage—e.g., where the basevoltage signal is analyzed separately with a low pass filter applied andwith a high pass filter applied, allowing for a separate determinationof the response voltage to the injected current, and of the base voltagedue to the current load. In certain embodiments, the voltagedetermination circuit 5518 is further structured to determine todetermine an injected voltage drop of the thermal fuse in response to anoutput of the high pass filter; and/or where the voltage determinationcircuit 5518 is further structured to determine the thermal fuseimpedance value in response to the injected voltage drop. In certainembodiments, the voltage determination circuit 5518 is furtherstructured to determine a load voltage drop of the thermal fuse 5520 inresponse to an output of the low pass filter, and/or where the systemfurther includes a load current circuit 5519 structured to determine aload current through the fuse in response to the thermal fuse impedancevalue (e.g., determined from the response voltage to the injectedcurrent), and further in response to the load voltage drop from the lowpass filter.

Referencing FIG. 54, an example system includes a vehicle 5402 having amotive electrical power path 5404; a power distribution unit 5406including a current protection circuit 5408 disposed in the motiveelectrical power path 5404, the current protection circuit 5408including a thermal fuse 5420 and a contactor 5422 in a seriesarrangement with the thermal fuse 5420. The example system furtherincludes a current source circuit 5416 electrically coupled to thethermal fuse 5420 and structured to inject a current across the thermalfuse 5420; and a voltage determination circuit 5518 electrically coupledto the thermal fuse 5420 and structured to determine at least one of aninjected voltage amount and a thermal fuse impedance value, where thevoltage determination circuit 5518 includes a high pass filter (e.g.,analog filter 5428, depicted in a bandpass filter 5426, but which mayadditionally or alternatively include a high pass filter) having acutoff frequency selected in response to a frequency of the injectedcurrent.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes where the voltage determination circuit 5518further includes a bandpass filter 5426 having a bandwidth selected tobound the frequency of the injected current. For example, where thefrequency of the injected current is 200 Hz, the bandpass filter 5426may be configured with cutoff frequencies of 190 Hz to 210 Hz, 195 Hz to205 Hz, 199 Hz to 201 Hz, within 5% of the injected frequency, and/orwithin 1% of the injected frequency. One of skill in the art, having thebenefit of the disclosures herein, can determine an appropriateinjection frequency and/or range of injection frequencies to beutilized, and values for the high pass filter and/or the band passfilter to provide an appropriately conditioned voltage responsedetermination to the injected current. Certain considerations forselecting an injected frequency and the band pass filter range include,without limitation, frequency components in electrical communicationwith the motive electrical power system including base frequencies andharmonics, the noise environment of the system, the desired accuracy ofthe thermal fuse impedance value determination, the dynamic response andcapability of the current injector, the dynamic response and attenuationcapability of the filters, the time available for performing aninjection event, a number of fuses coupled to the current injector(s)that are to be checked, the desired time response for determiningchanges in the fuse impedance value, and/or the amount of statisticaland/or frequency component analysis post-processing that is available onthe controller 5414.

An example system includes where the high pass filter includes an analoghardware filter 5428, and where the bandpass filter 5426 includes adigital filter 5430. For example, the analog hardware filter 5428 mayperform the high pass filtering function, and a downstream digitalfilter 5430 may perform a digital or analytical bandpass filteringfunction on the high pass filtered input. An example system includeswhere the high pass filter and the bandpass filter are both digitalfilters 5430. An example voltage determination circuit 5518 is furtherstructured to determine the thermal fuse impedance value in response tothe injected voltage drop from the high pass and band pass filteredinput. An example system includes a fuse characterization circuit 5418that stores a fuse resistance value and/or a fuse impedance value,and/or the fuse characterization circuit 5418 further updates the storedone of the fuse resistance value and the fuse impedance value inresponse to the thermal fuse impedance value. An example system includeswhere the fuse characterization circuit 5418 is further updates thestored one of the fuse resistance value and the fuse impedance value byperforming at least one operation such as: updating a value to thethermal fuse impedance value (e.g., instantaneously or periodicallyreplacing the stored value with the determined value); filtering a valueusing the thermal fuse impedance value as a filter input (e.g., movingcontinuously toward the determined value, such as with a selected timeconstant); rejecting the thermal fuse impedance value for a period oftime or for a number of determinations of the thermal fuse impedancevalue (e.g., where a low trust and/or anomalous value is determined,setting the value aside or ignoring it for a period of time or selectednumber of determinations, and/or later confirming the value if itappears to be consistent over time); and/or updating a value byperforming a rolling average of a plurality of thermal impedance valuesover time (e.g., utilizing a rolling buffer or other memory construct toreplace older determinations with updated determinations). An examplesystem includes where the power distribution unit 5406 further includesa number of thermal fuses 5420 disposed therein, and where the currentsource circuit 5416 is further electrically coupled to the number ofthermal fuses (which maybe a single current source selectively coupledto various fuses, and/or separate current sources controllable by thecurrent source circuit 5416). the example current source circuit 5416further configured to sequentially inject a current across each of thenumber of thermal fuses (e.g., to check the thermal fuse impedance valueand/or resistance for each of the fuses in a selected sequence). Anexample voltage determination circuit 5518 is further electricallycoupled to each of the number of thermal fuses, and further structuredto determine at least one of an injected voltage amount a thermal fuseimpedance value for each of the number of thermal fuses. An examplecurrent source circuit 5416 is further configured to sequentially injectthe current across each of the number of thermal fuses in a selectedorder of the fuses (e.g., the fuses need not be checked in anyparticular order, and need not be checked with the same frequency or thesame number of times). An example current source circuit 5416 furtherstructured adjusts the selected order in response to at least one of: arate of change of a temperature of each of the fuses (e.g., a fuse thatis changing temperature more quickly may be checked more frequently); animportance value of each of the fuses (e.g., a motive power fuse may bechecked more frequently than a non-critical accessory fuse); acriticality of each of the fuses (e.g., a mission disabling fuse may bechecked more frequently than another fuse); a power throughput of eachof the fuses (e.g., similar to the rate of change of temperature, and/orindicative of the potential for increased wear or aging of the fuse);and/or one of a fault condition or a fuse health condition of each ofthe fuses (e.g., a fuse having a suspected or active fault, and/or afuse that is worn or aged, may be checked more frequently to track theprogress of the fuse, confirm or clear the diagnostic, and/or to morerapidly detect or respond to a failure). An example current sourcecircuit 5416 is further structured to adjust the selected order inresponse to one of a planned duty cycle and an observed duty cycle ofthe vehicle (e.g., adjusting the fuse checking order and/or frequencybased on the planned duty cycle of the vehicle or the motive powercircuit, and/or based on the observed duty cycle of the vehicle or themotive power circuit, allowing adjustment for various applicationsand/or observed run-time changes). An example system includes where thecurrent source circuit 5416 is further structured to sweep the injectedcurrent through a range of injection frequencies (e.g., ensuringrobustness to system noise, informing a multi-frequency impedance modelof the fuse, and/or passively or actively avoiding injected noise ontothe power circuit including the fuse). An example current source circuit5416 is further structured to inject the current across the thermal fuseat a number of injection frequencies (e.g., similar to a sweep, butusing a selected number of discrete frequencies, which achieves some ofthe benefits of the sweep with more convenient filtering and processing,and includes updating the selected injection frequencies based on systemchanges such as loads, observed noise, and/or observed value of selectedfrequencies in characterizing the fuse). An example system includeswhere the current source circuit 5416 is further structured to injectthe current across the thermal fuse at a number of injection voltageamplitudes. The injection voltage amplitude may be coupled with theinjection current amplitude. Wherever an injection amplitude isdescribed throughout the present disclosure, it is understood that aninjection amplitude may be a current injection amplitude and/or avoltage injection amplitude, and in certain operating conditions thesemay be combined (e.g., selecting a voltage amplitude until a currentlimit in the current source is reached, selecting a current amplitudeuntil a voltage limit in the current source is reached, and/or followingan amplitude trajectory that may include a combination of voltage and/orcurrent). An example system includes where the current source circuit5416 is further structured to inject the current across the thermal fuseat an injection voltage amplitude determined in response to a powerthroughput of the thermal fuse (e.g., injecting a greater amplitude athigh load to assist a signal-to-noise ratio, and/or a lower amplitude athigh load to reduce the load on the fuse). An example system includeswhere the current source circuit 5416 is further structured to injectthe current across the thermal fuse at an injection voltage amplitudedetermined in response to a duty cycle of the vehicle.

Referencing FIG. 56, an example procedure includes an operation 5602 todetermine null offset voltage for a fuse current measurement system,including an operation 5604 to determine that no current is demanded fora fuse load for a fuse electrically disposed between an electrical powersource and an electrical load; and the operation 5604 includingdetermining a null offset voltage in response to the no current demandedfor the fuse load; and an operation 5606 to store the null offsetvoltage.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation to update a stored nulloffset voltage in response to the determined null offset voltage. Anexample procedure includes an operation to diagnose a component inresponse to the null offset voltage, for example where a high nulloffset voltage indicates that a component in the system may not beoperating properly. An example procedure includes an operation todetermine which one of a plurality of components is contributing to thenull offset voltage (e.g., by performing a null offset voltagedetermination with selected components coupled or de-coupled from thecircuit having the fuse being checked). An example procedure includes anoperation to determine that no current is demanded for the fuse load byperforming at least one operation such as: determining that a key-offevent has occurred for a vehicle including the fuse, the electricalpower source, and the electrical load; determining that a key-on eventhas occurred for the vehicle; determining that the vehicle is poweringdown; and/or determining that the vehicle is in an accessory condition,where the vehicle in the accessory condition does not provide powerthrough the fuse (e.g., a keyswitch accessory position for anapplication where the motive power fuse is not energized in theaccessory position).

Referencing FIG. 57, an example apparatus to determine offset voltage toadjust a fuse current determination includes a controller 5702 having afuse load circuit 5708 structured to determine that no current isdemanded for a fuse load, and to further determine that contactorsassociated with the fuse are open; an offset voltage determinationcircuit 5722 structured to determine an offset voltage corresponding toat least one component in a fuse circuit associated with the fuse, inresponse to the determining that no current is demanded for the fuseload; and an offset data management circuit 5724 structured to store theoffset voltage, and to communicate a current calculation offset voltagefor use by a controller to determine current flow through the fuse.

Referencing FIG. 58, an example procedure includes an operation 5802 toprovide digital filters for a fuse circuit in a power distribution unit,including an operation 5804 to inject an alternating current across afuse, where the fuse is electrically disposed between an electricalpower source and an electrical load; an operation 5806 to determine thebase power through a fuse by performing a low-pass filter operation onone of a measured current value and a measured voltage value for thefuse; and an operation 5808 to determine an injected current value byperforming a high-pass filter operation on one of the measured currentvalue and the measured voltage value for the fuse.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation to adjust parameters ofat least one of the low-pass filter and the high-pass filter in responseto a duty cycle of one of power and current through the fuse. An exampleprocedure includes an operation to sweep the injected alternatingcurrent through a range of injection frequencies. An example procedureincludes an operation to inject the alternating current across the fuseat a number of injection frequencies. An example procedure includes anoperation where the current source circuit is further structured toinject the current across the fuse at a number of injection voltageamplitudes. An example procedure includes an operation where the currentsource circuit is further structured to inject the current across thefuse at an injection voltage amplitude determined in response to a powerthroughput of the fuse. In certain embodiments, the low-pass filterand/or the high-pass filter are digital filters, and where the adjustingparameters of the digital filters includes adjusting values for thedigital filter(s). An example procedure includes further processing themeasured voltage value with a digital bandpass filter after performingthe high-pass filter, and determining a fuse resistance, fuse dynamicresistance, and/or fuse impedance value based on the high-pass and thenbandpass filtered measured voltage value.

Referencing FIG. 59, an example procedure includes an operation 5902 tocalibrate a fuse resistance determination algorithm, including: anoperation 5904 to store a number of calibration sets corresponding to anumber of duty cycle values, the duty cycles including an electricalthroughput value corresponding to a fuse electrically disposed betweenan electrical power source and an electrical load. Example calibrationsets include current source injection settings for a current injectiondevice operationally coupled to the fuse, including injectionfrequencies, injection duty cycles (e.g., on-time for each cycle),injection waveform shapes, fuse sequence operations (e.g., the order andfrequency to check each fuse), injection amplitudes, and/or injectionrun-times (e.g., the number of seconds or milliseconds for eachinjection sequence for each fuse, such as 130 ms, 20 ms, 1 second,etc.). The example procedure includes an operation 5908 to determine aduty cycle of a system including the fuse, the electrical power source,and the electrical load; an operation 5910 to determine injectionsettings for the current injection device in response to the number ofcalibration sets and the determined duty cycle (e.g., using theindicated calibration set according to the determined duty cycle, and/orinterpolating between calibration sets); and an operation 5912 tooperate the current injection device in response to the determinedinjection settings.

An example procedure further includes an operation where the calibrationsets further comprise filter settings for at least one digital filter,where the method further includes determining the fuse resistanceutilizing the at least one digital filter.

Referencing FIG. 60, an example procedure includes an operation 6002 toprovide unique current waveforms to improve fuse resistance measurementfor a power distribution unit. In certain embodiments, the procedureincludes an operation 6004 to confirm that contactors electricallypositioned in a fuse circuit are open, where the fuse circuit includes afuse electrically disposed between an electrical power source and anelectrical load, and/or an operation 6006 to determine a null voltageoffset value for the fuse circuit. An example procedure includes anoperation 6006 to conduct a number of current injection sequences acrossthe fuse, where each of the current injection sequences includes aselected current amplitude, current frequency, and current waveformvalue. An example procedure further includes an operation 6010 todetermine a fuse resistance value in response to the current injectionsequences and/or the null voltage offset value.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure further includes an operation to adjust filteringcharacteristics for a digital filter in response to each of the numberof current injection sequences, and to measure one of the fuse circuitvoltage or the fuse circuit current with the digital filter during thecorresponding current injection sequence using the adjusted filteringcharacteristics.

Referencing FIG. 61, an example system includes a vehicle 6102 having amotive electrical power path 6104; a power distribution unit including acurrent protection circuit 6108 disposed in the motive electrical powerpath 6104, where the current protection circuit 6108 includes a thermalfuse 6120 and a contactor 6122 in a series arrangement with the thermalfuse 6120. The example system includes a controller 6114 having acurrent source circuit 6116 electrically coupled to the thermal fuse6120 and structured to inject a current across the thermal fuse 6120,and a voltage determination circuit 6118 electrically coupled to thethermal fuse 6120 and structured to determine an injected voltage amountand a thermal fuse impedance value. The example voltage determinationcircuit 6118 is structured to perform a frequency analysis operation todetermine the injected voltage amount. Example and non-limitingfrequency analysis operations include applying analog and/or digitalfilters to remove frequency components of the fuse voltage that are notof interest and/or that are not related to the injected frequency.Example and non-limiting frequency analysis operations include utilizingat least one frequency analysis technique selected from the techniquessuch as: a Fourier transform, a fast Fourier transform, a Laplacetransform, a Z transform, and/or a wavelet analysis. In certainembodiments, a frequency analysis operation is performed on filteredand/or unfiltered measurements of the thermal fuse voltage.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes where the voltage determination circuit 6118further structured to determine the injected voltage amount bydetermining an amplitude of a voltage across the fuse at a frequency ofinterest; and/or where the frequency of interest is determined inresponse to a frequency of the injected voltage. An example systemincludes where the current source circuit 6116 is further structured tosweep the injected current through a range of injection frequencies. Anexample system includes where the current source circuit 6116 is furtherstructured to inject the current across the thermal fuse 6120 at anumber of injection frequencies. An example system includes where thecurrent source circuit 6116 is further structured to inject the currentacross the thermal fuse 6120 at a number of injection voltageamplitudes. An example system includes where the current source circuit6116 is further structured to inject the current across the thermal fuse6120 at an injection voltage amplitude determined in response to a powerthroughput of the thermal fuse 6120. An example system includes wherethe current source circuit 6116 is further structured to inject thecurrent across the thermal fuse 6120 at an injection voltage amplitudedetermined in response to a duty cycle of the vehicle 6102.

Referencing FIG. 62, an example system includes a vehicle 6202 having amotive electrical power path 6204; a power distribution unit including acurrent protection circuit 6208 disposed in the motive electrical powerpath 6204, the current protection circuit 6208 including a thermal fuse6220 and a contactor 6222 in a series arrangement with the thermal fuse.The example system further includes a controller 6214 having a currentsource circuit 6216 electrically coupled to the thermal fuse andstructured to determine that a load power throughput of the motiveelectrical power path 6204 is low, and to inject a current across thethermal fuse 6220 in response to the load power throughput of the motiveelectrical power path 6204 being low. The controller 6214 furtherincludes a voltage determination circuit 6218 electrically coupled tothe thermal fuse 6220 and structured to determine at least one of aninjected voltage amount and a thermal fuse impedance value, and wherethe voltage determination circuit 6218 includes a high pass filterhaving a cutoff frequency selected in response to a frequency of theinjected current.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes where the current source circuit 6216 is furtherstructured to determine the load power throughput of the motiveelectrical power path 6204 is low in response to the vehicle being in ashutdown state. An example system includes where the current sourcecircuit 6216 is further structured to determine the load powerthroughput of the motive electrical power path 6204 is low in responseto the vehicle being in a keyoff state. An example system includes wherethe current source circuit 6216 is further structured to determine theload power throughput of the motive electrical power path 6204 is low inresponse to a motive torque request for the vehicle being zero. Anexample system includes where the power distribution unit furtherincludes a number of fuses, and where the current source circuit 6216 isfurther structured to inject the current across each of the fuses in aselected sequence; and/or where the current source circuit 6216 isfurther structured to inject the current across a first one of theplurality of fuses at a first shutdown event of the vehicle, and toinject the current across a second one of the plurality of fuses at asecond shutdown event of the vehicle (e.g., to limit run-time of thecontroller 6214 during shutdown events that may be of limited duration,an example current source circuit 6216 checks only one or a subset ofthe fuses during a given shutdown event, only checking all of the fusesover a number of shutdown events).

Referencing FIG. 62, an example system includes a vehicle 6202 having amotive electrical power path 6204; a power distribution unit including acurrent protection circuit 6308 disposed in the motive electrical powerpath 6204, where the current protection circuit 6208 includes a thermalfuse 6220 and a contactor 6222 in a series arrangement with the thermalfuse 6220. An example system further includes a controller 6214 having acurrent source circuit 6218 electrically coupled to the thermal fuse6220 and structured to inject a current across the thermal fuse 6220;and a voltage determination circuit 6218 electrically coupled to thethermal fuse 6220 and structured to determine at least one of aninjected voltage amount and a thermal fuse impedance value. The examplevoltage determination circuit 6218 includes a high pass filter having acutoff frequency selected in response to a frequency of the injectedcurrent. The example controller 6214 further includes a fuse statuscircuit 6219 structured to determine a fuse condition value in responseto the at least one of the injected voltage amount and the thermal fuseimpedance value. For example, a correlation between the fuse resistance(and/or dynamic resistance or impedance) may be established for aparticular fuse or type of fuse, and the example fuse status circuit6219 determines the fuse condition value in response to the observedfuse resistance or other related parameter. In certain embodiments, thefuse status circuit 6219 may additionally include other information,such as the power throughput accumulated through the fuse, powertransient events accumulated and/or power excursion events accumulatedthrough the fuse, temperature events and/or temperature transientsaccumulated by the fuse, and/or an operational longevity parameter suchas hours of operation, miles of operation, hours of powered operation,or the like.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes where the fuse status circuit 6219 is furtherstructured to provide the fuse condition value by providing at least oneof a fault code or a notification of the fuse condition value (e.g.,storing a parameter, communicating a fault parameter to a datalink,and/or providing a fault parameter to a service tool). An example fusestatus circuit 6219 further adjusts a maximum power rating for themotive electrical power path 6204, a maximum power slew rate for themotive electrical power path; and/or adjusts a configuration of thecurrent protection circuit in response to the fuse condition value(e.g., sharing a load between parallel fuses, bypassing the fuse atlower thresholds for power or power transients, etc.). An example powerdistribution unit further includes an active cooling interface 6224, andwhere the fuse status circuit 6219 further adjusts the active coolinginterface 6224 in response to the fuse condition value (e.g., providingadditional cooling for an aging fuse, and/or lowering a threshold for anactive cooling increase request for an aging fuse). An example fusestatus circuit 6219 is further structured to clear the at least one ofthe fault code or the notification of the fuse condition value inresponse to the fuse condition value indicating that the fuse conditionhas improved (e.g., where a previous indication from the fuse conditionvalue indicated degradation, but continued observations indicate thatdegradation of the fuse is not present; upon a reset by an operator or aservice technician, such as an indication that the fuse has been checkedor changed, etc.). An example fuse status circuit 6219 is furtherstructured to clear the at least one of the fault code or thenotification of the fuse condition value in response to a service eventfor the fuse (e.g., through a service tool, planned sequence of inputs,or the like); where the fuse status circuit 6219 is further structuredto determine a fuse life remaining value in response to the fusecondition value (e.g., through a correlation of the fuse condition valueto the fuse life remaining value, and/or using a cutoff or thresholdvalue of the fuse condition value to trigger an end-of-life condition orwarning; for example it may be determined that a particular value of thefuse condition value indicates that the fuse is at 90% of a plannedlife, has 500 hours of operation remaining, etc.); where the fuse statuscircuit 6219 is further structured to determine the fuse life remainingvalue further in response to a duty cycle of the vehicle (e.g., incertain embodiments a heavier vehicle duty cycle will consume theremaining fuse life more quickly, which may be accounted for indetermining the fuse life remaining value, and which may depend upon theunits of fuse life remaining such as operating hours versus calendardays, and/or upon the notification type—e.g., a service light, aquantitative time remaining, etc.—to a service technician, operator, orthe like); and/or where the fuse status circuit 6219 is furtherstructured to determine the fuse life remaining value further inresponse to one of: an adjusted maximum power rating for the motiveelectrical power path, an adjusted maximum power slew rate for themotive electrical power path, and/or an adjusted configuration of thecurrent protection circuit (e.g., where the fuse status circuit 6219 hasadjusted system parameters such as power throughput, fuse loading and/orbypass configurations or thresholds, and/or cooling strategies, the fusestatus circuit 6219 may account for the estimated life extension of thefuse due to these or any other mitigating strategies in place).

Referencing FIG. 63, an example system includes a vehicle 6302 having amotive electrical power path 6304; a power distribution unit including acurrent protection circuit 6308 disposed in the motive electrical powerpath 6304, where the current protection circuit further includes athermal fuse 6320 and a contactor 6322 in a series arrangement with thethermal fuse 6320. The example system further includes a controller 6314having a fuse thermal model circuit 6316 structured to determine a fusetemperature value of the thermal fuse 6320, and to determine a fusecondition value in response to the fuse temperature value. An examplesystem includes a current source circuit 6318 electrically coupled tothe thermal fuse 6320 and structured to inject a current across thethermal fuse 6320; a voltage determination circuit 6319 electricallycoupled to the thermal fuse 6320 and structured to determine at leastone of an injected voltage amount and a thermal fuse impedance value,and where the voltage determination circuit 6319 includes a high passfilter having a cutoff frequency selected in response to a frequency ofthe injected current. An example fuse thermal model circuit 6316 furtherdetermines the fuse temperature value of the thermal fuse further inresponse to the at least one of the injected voltage amount and thethermal fuse impedance value. An example system includes where the fusethermal model circuit 6316 is further structured to determine the fusecondition value by counting a number of thermal fuse temperatureexcursion events. Example thermal fuse temperature excursion eventsinclude: a temperature rise threshold value within a time thresholdvalue, a temperature of the thermal fuse exceeding a threshold value,and/or more than one threshold of these (e.g., counting more severeoccurrences as more than one temperature excursion event). An examplesystem includes the fuse thermal model circuit is further determiningthe fuse condition value by integrating the fuse temperature value,integrating a temperature based index (e.g., based on temperaturesand/or temperature change rates), and/or integrating the fusetemperature value for temperatures above a temperature threshold.

Referencing FIG. 64, an example previously known system is depictedhaving a contactor and fuse combination. The example system, forpurposes of illustration, is provided as a part of a power distributionunit (PDU) 6402 for an electric or partially electric vehicle. Thesystem includes electrical storage (e.g., a battery) and a motorproviding motive power for the vehicle. The electrical storage (or powerstorage) device may be of any type, including a battery, a fuel cell,and/or a capacitor (e.g., a super-capacitor or a hyper-capacitor), andcombinations of these (e.g., a capacitor included in the circuit toassist in peak power production or management of transient operations).In certain embodiments, the electrical storage device is rechargeable(e.g., any rechargeable battery technology such as lithium ion, nickelmetal-hydride, or nickel-cadmium) or recoverable (e.g., a chemical basedfuel cell having reversible chemistry to recover charge generatingcapability). In the example system, the battery operates as a DC deviceand the motor operates as an AC device, with an inverter positionedtherebetween to condition power for the motor. The example systemincludes filter capacitors 6404 providing conditioning for the mainpower circuit. The example system includes a low side contactor and ahigh side contactor. The high side contactor is in series with a fuse6410 providing overcurrent protection for the circuit. The examplesystem further includes a pre-charge circuit, depicted as a pre-chargerelay 6408 and a pre-charge resistor 6406. In certain embodiments, thepre-charge relay 6408 is engaged before the high side contactor isengaged, allowing capacitive elements of the overall circuit to energizethrough the pre-charge resistor 6406, limiting in-rush currents or othercharge-up artifacts on system start-up. It can be seen that overcurrentprotection is provided by the system through the fuse 6410, and thecharacteristics of the fuse 6410 set the overcurrent protection for themotive circuit through the PDU. Additionally, the contactors are exposedto connection and disconnection events, including arcing, heating, andother wear.

Referencing FIG. 65, an example PDU 6402 of the present disclosure isschematically depicted. The example PDU 6402 is utilizable in a systemsuch as that depicted in FIG. 64. The example PDU of FIG. 65 includes abreaker/relay 6502 component on the high side. The example arrangementof FIG. 65 is non-limiting, and any arrangement of the breaker/relay6502 that provides designed overcurrent protection for a system usingany of the principles described throughout the present disclosure iscontemplated herein. The example PDU 6402 of FIG. 65 omits a fuse inseries with a contactor, utilizing the breaker/relay 6502 forovercurrent protection. Any breaker/relay 6502 as described throughoutthe present disclosure may be utilized in a system such as that depictedin FIG. 65. The PDU 6402 of FIG. 65 additionally utilizes a pre-chargerelay 6408 and a pre-charge resistor 6406, similar to that depicted inFIG. 64. In the example of FIG. 65, the breaker/relay 6502 is inparallel with the pre-charge circuit, and the relay portion of thebreaker/relay 6502 may be engaged after the system has charged throughthe pre-charge circuit. As described throughout the present document,the breaker/relay 6502 provides for continuous and selectableovercurrent protection, while providing for full rated operationthroughout range of designed operating current for the system. Inpreviously known systems, a contactor/fuse arrangement necessarilyprovides for a gap in the operating range, either pushing fuseactivation at least partially down into the operating current range, ormoving fuse activation away from the rated range and providing for a gapin overcurrent protection above the rated current for the system.Additionally, as described throughout the present disclosure, thebreaker/relay 6502 can provide for multiple current protection regimes,selectable current protection based on operating conditions, andprovides for reduced wear on the contact elements of the breaker/relayrelative to previously known contactors. Accordingly, a system such asthat depicted in FIG. 65 can provide reliable, responsive, andrecoverable overcurrent protection relative to previously known systems.

Referencing FIG. 66, an example PDU 6402 is schematically depicted. Theexample PDU 6402 is utilizable in a system such as that depicted in FIG.1, and has features that may be additional to or alternative to featuresdescribed with regard to FIG. 65. The example of FIG. 66 depicts anexternal input to the breaker/relay 6502 (Inhibit, with a schematicdepiction of a keyswitch input 6504, in the example). The breaker/relay6502 is responsive to the external signal in a configurable manner. Forexample, a keyswitch ON operation may be utilized to energize thebreaker/relay 6502—either directly (e.g., hard-wiring the keyswitchcircuit through a coil of the breaker/relay) or indirectly (e.g.,receiving a network value representing the keyswitch position, receivinga voltage signal representing the keyswitch position, etc.), therebycharging the motive power circuit. In another example, a keyswitch OFFoperation may be utilized to de-energize the breaker/relay 6502, therebyremoving power from the motive power circuit. The external signal may beof any type or of several types, including external commands generatedfrom any portion of the system, calculated values indicating whetherpower should be supplied or cut (e.g., a service event, a maintenanceevent, an accident indicator, an emergency shutdown command, a vehiclecontroller request, a device protection request for some device on thevehicle, a calculation that a temperature, voltage value, or currentvalue has exceeded a threshold, etc.). The external signal may besupplied as a hard-wired signal (e.g., an electrical connection with avoltage representing the signal value), and/or as a communication (e.g.,a datalink or network communication) which may be a wired or wirelesscommunication, and may be generated by a controller on the PDU 6402 orexternal to the PDU 6402 (e.g., a vehicle controller, a power managementcontroller, or the like). The example of FIG. 66 does not depict apre-charge circuit for convenience of illustration, but embodiments suchas those depicted in FIG. 65 or FIG. 66 may have a pre-charge circuit oromit a pre-charge circuit depending upon the characteristics of thesystem, the design goals and requirements for the system, and the like.

Referencing FIG. 67, an example schematic block diagram of abreaker/relay is depicted. The example breaker/relay of FIG. 67 includesa power bus 6702 (e.g., the high voltage, motive power, load power,etc.) that operates the high voltage throughput and is connected ordisconnected through a contact which is schematically depicted. Avoltage that is a “high voltage” on the power bus may be any value, anddepends upon the load being driven and other selection parameters forthe system. In certain embodiments, a high voltage is any voltage above42V, above 72V, above 110V, above 220V, above 300V, and/or above 360V.The voltage range may be different for a motive power load versus anauxiliary load (e.g., a PTO device, pump, or the like) and may be higheror lower than these ranges. In the example, the standard on/off 6504 orcontrol voltage is depicted on the left side (depicted as 12 V, althoughany value such as 6 V, 12 V, 24 V, 42 V may be utilized). The standardvoltage 6504 is depicted for purposes of illustration, although thestandard voltage may additionally or alternatively be a datalink ornetwork input (e.g., where the breaker/relay has independent access tocontrol power) in communication with a controller of the breaker/relay.In certain embodiments, the standard voltage 6504 will be the samevoltage as experienced at the keyswitch, by a vehicle controller, byauxiliary (e.g., not-motive or non-load) components in a system, or thelike. In certain embodiments, the standard voltage 6504 will be thekeyswitch 6504 signal. The standard voltage 6504 may be configured to bereceived through an input control isolation 6710.

Further in the example of FIG. 67, an auxiliary off isolation 6708 isdepicted, which provides an input for auxiliary control of thebreaker/relay. In certain embodiments, the auxiliary off isolation 6708is coupled to an electrical input 6704, such as a selectable input atthe standard voltage, an output from a controller (e.g., the controllerproviding electrical power as an output at a selected voltage to theauxiliary off isolation). In certain embodiments, the auxiliary offisolation 6708 may utilize a datalink or network input. In certainembodiments, for example where the breaker/relay has an internalcontroller, the standard on/off 6504 and the auxiliary off isolationinput 6704 may be the same physical input—for example where a datalinkinput, network input, and/or controllable electrical signal (e.g., acontrolled voltage value) provide the breaker/relay with information todetermine the current requested state of the breaker/relay. In certainembodiments, the breaker/relay is a hardware only device that accepts afirst voltage value at the standard on/off position, a second voltagevalue at the auxiliary off position, and responds through the hardwareconfiguration of the breaker/relay to perform selected operations.

In the example of FIG. 67, the standard on/off input 6504 and theauxiliary off input 6704 include circuit protection components (e.g.isolations 6708, 6710), such as surge protection and polarityprotection. The example breaker/relay includes a logic circuit thatprovides for energizing the relay (closing the contact on the power bus)when the standard on/off input 6504 is high, and de-energizing the relay(opening the contact on the power bus) when either the standard on/offinput 6504 is low or the auxiliary off input is low 6704. In the exampleof FIG. 67, the logic circuit is depicted schematically, and may beimplemented as hardware elements in the breaker/relay. Additionally oralternatively, a controller in the breaker/relay may interpret inputvoltages, datalink signals, and/or network communications to implementthe logic and determine whether to open or close the relay. The logic inthe present system is depicted as a “normally-open” relay that utilizespower to close (make contact), although the breaker/relay may beconfigured as a “normally-closed”, latching, or any other logicalconfiguration. Additionally or alternatively, the standard on/off inputs6504 and/or the auxiliary off inputs 6704 may utilize logical highs orlogical lows to implement operations of the breaker/relay.

The example breaker/relay of FIG. 67 additionally depicts a currentsensing device 6706 (“current sensing”) which may be a current sensor onthe bus, a calculated current value based on other system parameters, acurrent value passed to the breaker/relay and/or a controlleroperatively coupled to the breaker/relay, or any other device,mechanism, or method to determine current values on the bus. In theexample of FIG. 67, the current sensing device 6706 is coupled to the“trigger level ‘off’” portion of the logical circuit, and operates tode-energize the relay when a high current value is sensed. The sensedhigh current value may be either a single threshold, for example asdetermined by the hardware in the logic circuit, and/or a selectablethreshold, for example determined by a controller based on operatingconditions or other values in the system. It can be seen that, eitherthrough hardware or utilizing a controller, functions of the sensedcurrent value such as a rate of change, accumulated current value over athreshold, etc. may be utilized additionally or alternatively to thesingle sensed current value. It can be seen that a breaker/relay such asthat depicted in FIG. 67 provides for controllable opening of the powerbus circuit at a selected threshold current value and/or functionsthereof, allowing for continuous operation throughout the range of ratedcurrent for the system. Additionally, a breaker/relay such as thatdepicted in FIG. 67 provides for a controllable disconnection of thepower bus for any selected parameter which may not be current related,such as emergency shutdown operations, a request from somewhere else inthe system (e.g., a vehicle controller), service or maintenanceoperations, or any other selected reason. Certain embodiments throughoutthe present disclosure provide for additional features of thebreaker/relay, any one or more of which may be included in an embodimentsuch as that depicted in FIG. 67.

Referencing FIG. 68, an example breaker/relay is depicted schematicallyin a cutaway view. The example breaker/relay includes generally aswitching portion 6820 (upper half, or “breaker”) and an actuatingportion 6822 (lower half, or “relay”). A few example components of thebreaker/relay are depicted and described for illustration. The examplebreaker/relay includes a coil 6816 and magnet core 6818 in the relayportion. In the example, energizing the coil 6816 actuates the relay,pulling the armature 6814 down to the magnet core 6818. The armature6814 is coupled to the movable contact 6810 in the upper portion, and isthereby moved into contact with the fixed contact 6812, completing thecircuit and allowing current flow through the power bus. In the exampleof FIG. 68, the movable contact 6810 is pressed into the fixed contact6812 by a contact force, which is a biasing spring 6804 of a selectablebiasing force in the example of FIG. 68. The movable contact 6810 can belifted from the fixed contact 6812 with sufficient force, compressingthe contact force spring 6804, even if the armature 6814 is in theengaged (lower) position. The example of FIG. 68 depicts the armature6814 in the disengaged (upper) position, where the movable contact 6810is open or not in contact with the fixed contact 6812.

The breaker portion 6820 of the breaker/relay includes a number ofsplitter plates 6806 in proximity to a body of the main contact, and apermanent magnet system 6802 surrounding the splitter plates 6806 and/orthe arcing path between the contact gap and the splitter plates 6806.During engagement or disengagement of the movable contact 6810 when thepower bus is energized, the body of the main contact cooperates with thesplitter plates 6806, in the presence of the magnetic fields provided bythe permanent magnet system 6802, to dissipate and distribute theresulting arc, greatly reducing wear, degradation, and damage of thecontacts. It has been shown that the combined aspects of the breakerportion greatly extend the life of the contacts and the switchingchamber (e.g., due to lower arcing heat load over the life of thebreaker/relay).

The current passing through the power bus generates a repulsive forcebetween the contacts, or a Lorentz force. The Lorentz force is a complexfunction of the contact area of the contacts and the current valuethrough the power bus. When the current is very high, the Lorentz forcebetween the contacts sufficiently compresses the contact force spring6804 to force the movable contact 6810 to lift off of the fixed contact6812 and cause the relay to momentarily open. It has been found that thecontact force spring 6804 can be readily tuned to provide for a physicaldisconnect of the contacts at a selectable value. Additionally oralternatively, the contact area between the contacts and other geometricaspects of the contacts can be manipulated to select or adjust thephysical disconnect current. However, in certain embodiments, selectionof the contact force spring 6804 provides for a straightforward tuningof the physical disconnect current. In certain embodiments, selection ofthe contact force spring 6804 includes changing the spring to change thephysical disconnect current. Additionally or alternatively, the contactforce spring 6804 can be adjusted in situ (e.g., compressing orreleasing the spring axially) to adjust the physical disconnect current.

In certain embodiments, after the physical disconnect event (e.g., themovable contact 6810 is forced away from the fixed contact 6812,compressing the contact force spring 6812, while the armature 6814 is inthe lower or contact position), the current through the power bus fallsrapidly, and the Lorentz force decreases, causing the movable contact6810 to be pushed by the contact force spring 6804 back toward anengaged position. In certain embodiments, the current sensor 6706 willhave detected the high current event, triggering the coil 6816 tode-energize, and moving the armature 6814 back up to the disengagedposition. Accordingly, as the movable contact 6810 returns to theengaged position, the armature 6814 has already moved it away such thatthe movable contact 6810 does not touch the fixed contact 6812 after aphysical disconnect event. In certain embodiments, the thresholddetected by the current sensor 6706 to disengage the armature 6814 islower than the physical disconnect current, giving the armature 6814 a“head start” and decreasing the likelihood of a re-contact of themovable contact 6810 with the fixed contact 6812. In many systems, are-contact between the movable contact 6810 and the fixed contact 6812during a very high current event can result in significant damage to thebreaker/relay and/or welding of the contacts.

Referencing FIG. 69, an example breaker/relay is depicted showing therelative movement of the armature and the movable contact. In theexample, the armature at the top enforces the movable contact away fromthe fixed contact, resulting in a disconnection of the power bus. Thearmature at the bottom pulls the moving contact down to engage the fixedcontact, resulting in a connection of the power bus. The motion arrow6904 in FIG. 69 references the movement of the armature that will occuras the armature moves from the open state to the closed state after thecoil is energized. Any reference throughout the disclosure to “up” or“down” are for clarity of description, and do not reference actualvertical relationships of any components of the breaker/relay. Abreaker/relay may be positioned such that movement of the armature isalong any axis, including up-down, down-up, a horizontal orientation,and/or any other orientation. In certain embodiments, the armaturereturns to the up or disengaged position utilizing a passive element,such as a biasing spring or reverse spring (e.g., positioned between thearmature and the permanent magnet, and/or a housing of one or more ofthese), resulting in a “normally-open” logical operation for thebreaker/relay. The biasing spring or reverse spring does not appear inthe schematic cutaway view of FIG. 69. As described throughout thepresent disclosure, the breaker/relay may be normally-open,normally-closed, latching, or in any other logical configuration, withappropriate adjustments to the hardware and/or control elements toprovide such a configuration.

Referencing FIG. 69A, an example breaker/relay is depicted in a closedposition. The armature in the example of FIG. 69A has moved down, andthe movable contact 6810 has additionally moved down with the armature6814 to an engaged position with the fixed contact, closing the circuitand allowing power to pass through the power bus. The contact forcespring 6804 in the position depicted in FIG. 69A is compressed,providing a contact force to the movable contact 6810 against the fixedcontact. It can be seen that the movable contact is provided withmovement space, where a force sufficient to overcome the contact force6804 spring can lift the movable contact 6810 off of the fixed contact,thereby opening the circuit and preventing power to pass through thepower bus.

Referencing FIG. 70, an operating diagram for a previously knowncontactor-fuse system and a breaker/relay system consistent withembodiments of the present disclosure are depicted schematically. In theexample of FIG. 70, an operating current bar is depicted at the left,having two general operating regimes—operation within rated currentvalues (e.g., within designed current limits for a system, such asregions 7004, 7006) and operation above rated current values (e.g.,region 7008). Additionally, in the example of FIG. 70, operations withinthe rated current are sub-divided into a lower region 7004 and an upperregion 7006. In the example of FIG. 70, the lower region 7004 and upperregion 7006 are illustrative examples to depict operating modes withinthe rated current region—for example the lower region 7004 may beassociated with lower power operation such as operation of accessoriesand the upper region 7006 may be associated with higher power operationsuch as provision of motive power or pumping power. The regions 7004,7006 provide for a notional distinction between operating conditions,and the actual operations that occur within the lower region 7004 andupper region 7006 are not important for the illustration of FIG. 70. Forexample, an upper region 7006 for one illustrative system may be motivepower to move a vehicle (e.g., where the lower region 7004 is anotherfunction such as power to communications or accessories), where a lowerregion 7004 for another illustrative system may be motive power to movea vehicle (e.g., where the upper region 7006 is another function such ascharging or high performance motive power).

In the example of FIG. 70, an operation region for the contactor-fusesystem is depicted in the middle. The contactor provides for fulloperation up to the rated power. A design choice may allow for thecontactor to provide operation slightly above rated power (e.g., wheresystem risk is accepted to provide higher capability) or slightly belowrated power (e.g., where system performance is compromised to protectthe system components). The contactor-fuse system further includes anoperating region for the fuse, where the fuse activates at a selectedcurrent value. It can be seen that an operational gap 7002 occurs, wherethe fuse does not activate due to the low current value, but thecontactor also does not support operations in the gap 7002 region. Thegap 7002 can only be closed by overlapping operation of the contactorand/or the fuse, necessarily compromising the system risk profile orperformance. If the fuse region is extended lower, then rated operationunder certain duty cycles may trigger a fuse event and loss of mission.Additionally, as the contactor and fuse experience wear or degradation,the operating region for the contactor-fuse system will move, resultingin inconsistent system performance, loss of protection, and/orunnecessary fuse events. Additionally, the failure mode of a fuseresults in extended exposure of the system to high currents due to thefuse melt period and extended arcing time through the activating fuse.Finally, operations of the contactor at the upper range of the contactoroperating region results in undesirable heating and degradation of thecontactor.

In the example of FIG. 70, an operating region for a breaker/relayconsistent with certain embodiments of the present disclosure isdepicted. The breaker/relay provides for a smooth and selectablefunctionality throughout the operating current bar. The breaker/relayprovides for a highly capable contact that does not operate near theupper region of its current capacity, reducing heating and degradationfrom high, within rated range, operations, such as in the upper region7006. Additionally, the current sensor and related disconnect operationsallow for a selectable disconnection when operation is above the ratedcurrent for the system. Further, a physical disconnect current isavailable (e.g., reference FIG. 68 and the associated disclosure) thatprovides for immediate disconnection of the power bus at very highcurrent values. In certain embodiments, arc dissipation features of thebreaker/relay additionally provide for a faster and less damagingdisconnect event than experienced by previously known contactor-fusearrangements. Additionally, the breaker/relay provides for a recoverabledisconnect operation, where a mere command to the breaker/relay willagain provide connection without a service event. Accordingly, if thesystem failure causing the high current event is resolved or consistentwith a restart, the system can resume operations with the breaker/relayas soon as desired, without having to diagnose a fuse event or changeout the fuse.

Referencing FIG. 71, an example procedure 7100 is depicted to disconnecta power bus. The example procedure 7100 includes an operation 7102 todetect a current value, for example utilizing a current sensor(reference FIG. 68). The procedure 7100 further includes an operation7104 to determine if an overcurrent event is detected. For example, thedetected current value, a function thereof, or a calculated parameterdetermined in response to the current value, can be compared to athreshold value to determine if an overcurrent event is detected. Theexample procedure 7100 further includes an operation 7106 to command thecontacts open, for example by de-energizing a coil and thereby moving anarmature to a position that opens the contacts. The overcurrentthreshold may be any value, and may be modified in real-time and/or inaccordance with operating conditions. The value for the overcurrentthreshold depends upon the application and the components in the system.Example and non-limiting overcurrent values include 100 A, 200 A, 400 A,1 kA (1,000 amps), 1.5 kA, 3 kA, and 6 kA.

Referencing FIG. 72, an example procedure 7200 is depicted to perform aphysical disconnect. The example procedure 7200 includes an operation7202 to accept current throughput, for example as current passingthrough coupled contacts in a power bus. The example procedure 7200further includes an operation 7204 to determine whether the currentresulting force (e.g., a Lorentz force between a movable contact and afixed contact) exceeds a contact force (e.g., as provide by a contactforce spring). The example procedure 7200 further includes an operation7206 to open the contacts through a physical response—for example as theLorentz force overcoming the contact force spring and moving the movablecontact away from the fixed contact. The physical disconnect current maybe any value, and depends upon the application and the components in thesystem. Example and non-limiting physical disconnect currents include400 A, 1 kA, 2 kA, 4.5 kA, 9 kA, and 20 kA.

Referencing FIG. 73, an example procedure 7300 is depicted to opencontacts in response to an overcurrent event, and/or in response to anyother selected parameters. The example procedure 7300 includes anoperation 7302 to power a system on, for example via a keyswitch orother circuit, and/or via recognition of a keyswitch ON condition. Theprocedure 7300 further includes an operation 7304 to determine whethercontact enabling conditions are met, for example immediately after thekeyswitch ON, after a selected time period, after a system pre-chargeevent is determined to be completed, and/or according to any otherselected conditions. In certain embodiments, where the operation 7304determines that contact enabling conditions are not met, the procedure7300 holds on operation 7304 until contact enabling conditions are met.Any other response to operation 7304 determining that contact enablingconditions are not met is contemplated herein, including requesting apermission to enable contact conditions, setting a fault code, or thelike. In response to operation 7304 determining that contact conditionsare met, procedure 7300 further includes an operation 7306 to close thecontacts (e.g., energizing a coil to move an armature), and an operation7202 to accept current throughput. The example procedure 7300 furtherincludes operation 7200 performing a physical disconnect if the acceptedcurrent is high enough, and proceeds to operation 7102 to detect acurrent value through the power bus. The procedure 7300 further includesan operation 7104 to determine if an overcurrent event is detected(operation 7104, in certain embodiments, may be set at a lower currentvalue than the physical disconnect current tested at operation 7200). Inresponse to the operation 7104 determining that an overcurrent event isdetected, procedure 7300 includes an operation 7312 to command thecontacts open. In response to operation 7104 determining that anovercurrent event is not detected, procedure 7300 includes an operation7308 to detect auxiliary commands (e.g., an auxiliary off input), and anoperation 7310 to determine if an auxiliary command is present to openthe contacts (e.g., a logical high, logical low, specified value, lackof a specified value, etc.). In response to the operation 7310determining that an auxiliary command is present to open the contacts,procedure 7300 includes the operation 7312 to command the contacts open.In response to the operation 7310 determining that an auxiliary commandis not present to open the contacts (e.g., branch “CONTINUE OPERATIONS”in the example of FIG. 73) procedure returns to operation 7306.

Referencing FIG. 74, an example procedure 7400 to restore operations ofa breaker/relay after a contact opening event. The example procedure7400 includes an operation 7300 to open the contacts of thebreaker/relay, for example an operation wherein the contacts are openeddue to a physical disconnect, an overcurrent detection, and/or anauxiliary off command. The procedure 7400 further includes an operation7402 to determine if contact reset conditions are present. Example andnon-limiting operations 7402 include determining that contact enablingconditions are met, determining that a fault code value has been reset,determining that a system controller is requesting a contact reset,and/or any other contact reset conditions. The procedure 7400 furtherincludes an operation 7404 to close the contacts, for example byproviding power to the coil to move the armature.

Referencing FIG. 75, an example previously known mobile power circuit isdepicted. The example mobile power circuit is similar to the mobilepower circuit depicted in FIG. 64. The example of FIG. 75 includes ajunction box housing the pre-charge circuit, a high side relay, and alow side relay. In certain embodiments, the pre-charge circuit and thehigh side relay are provided in a housing within the junction box. Inthe example of FIG. 75, a fuse 6410 provides overcurrent protection onthe high side, and is housed with the main relays and the prechargeresistor 6406 within a PDU housing 7500.

Referencing FIG. 76, an example mobile power circuit including abreaker/relay 6502 disposed in the high side circuit, and a secondbreaker/relay 6502 positioned in the low side circuit. Eachbreaker/relay 6502, in certain embodiments, provides continuousovercurrent control throughout the operating region of the mobileapplication as described throughout the present disclosure.Additionally, it can be seen that the low side breaker/relay 6502provides for overcurrent protection in all operating conditions,including during a pre-charge operation when the high side breaker/relay6502 may be bypassed so the mobile power circuit can pre-charge throughthe pre-charge resistor 6406. In certain embodiments, both the high sidebreaker/relay 6502 and the low side breaker/relay 6502 provideadditional benefits such as rapid arc dispersion, low wear duringconnection and disconnection events, and improved heatingcharacteristics during high, but in rated range, current operation ofthe mobile circuit.

Referencing FIG. 77, an example power distribution arrangement for amobile application is depicted. The embodiment of FIG. 77 is similar tothe embodiment of FIG. 76, with a high side breaker/relay 6502 and a lowside breaker/relay 6502. Four operating regimes of the embodiment ofFIG. 77 are described herein, including pre-charge operations (e.g., atsystem power-on for the mobile application), powering operations forloads (e.g., providing motive power or auxiliary power for the mobileapplication), regeneration operations (e.g., recovering power from amotive load or auxiliary load), and charging operations (e.g.,connection of a dedicated charger to the system). In the example of FIG.77, the low side breaker/relay 6502 has an associated current sensor6706. In the example of FIG. 77, the low side breaker/relay 6502 is inthe loop during all operations, and can provide current protection forany operating conditions. To save costs, a current sensor for the highside breaker/relay 6502 can be omitted. In certain embodiments, forprotection of the breaker/relay contacts 6502, a local current sensormay be included for each breaker/relay 6502, to provide for operationsto protect the contacts in the event of a physical current disconnection(e.g., reference FIG. 70). It can be seen that additional contactorsand/or breaker/relays may be provided beyond those shown—for example toisolate the charge circuit, to route power through selected ones of themotive loads and/or auxiliary loads, and/or to prevent power flowthrough an inverter (not shown) during charging operations. Additionallyor alternatively, certain components depicted in FIG. 77 may not bepresent in certain embodiments. For example, a low-side contactor on thecharge circuit may not be present, and any one or more of the motiveloads (traction motor drive) or auxiliary loads may not be present.During a pre-charge operation, a pre-charge contactor 7702 may be closedwhile the high-side breaker/relay 6502 is open, where the low-sidebreaker/relay 6502 provides for current protection (in addition or as analternative to a pre-charge fuse) during pre-charge operations. Duringcharging operations, the low-side breaker/relay 6502 provides currentprotection, while the high-side breaker/relay 6502 is bypassed by thecharging circuit.

Referencing FIG. 78, an example power distribution management for amobile application is depicted. The embodiment of FIG. 78 is similar tothe embodiment of FIG. 77, except that the high side breaker/relay 6502is in the loop during all operations, and the low side breaker/relay6502 is not in the loop during charging operations. In the example ofFIG. 78, the high side breaker/relay 6502 may include current sensingassociated therewith to provide protection for the contacts during aphysical current disconnection. In certain embodiments, depending uponthe circuit dynamics of the mobile application, the current sensor 6706depicted on the low side may be sufficient to provide protection for thecontacts of the high side breaker/relay 6502 without a dedicated currentsensor for the high side breaker/relay 6502. During pre-chargeoperations for the embodiment of FIG. 78, current protection is notpresent, or is provided by a pre-charge fuse. During charging operationsfor the embodiment of FIG. 78, current protection is provided by thehigh-side breaker/relay 6502.

Referencing FIG. 79, an example power distribution management for amobile application is depicted. The embodiment of FIG. 79 is similar tothe embodiment of FIG. 77, except that the high side breaker/relay 6502is exchanged for a standard contactor. In the example of FIG. 79, thelow side breaker/relay 6502 provides for current protection during alloperating conditions, and the system otherwise uses conventionalcomponents. In certain embodiments, improved current protectioncapability is desirable, but contactor wear may not be as much of aconcern, and a trade-off for inexpensive contactors at other positionsin the mobile power circuit away from the low side breaker/relay 6502may be an acceptable solution. Additionally, the presence of the lowside breaker/relay 6502 in the circuit for all operating conditions canreduce the wear on the conventional contactors in the mobile powercircuit through timing of connections such that the low sidebreaker/relay 6502 reduces the number of connection and disconnectionevents on other contactors while the system is charged.

Referencing FIG. 80, an example power distribution management for amobile application is depicted. The embodiment of FIG. 80 is similar tothe embodiment of FIG. 78, except that the low side breaker/relay isreplaced with a contactor, and the low side charging circuit is routedthrough the low side contactor. The low side charging circuit may bypassthe low side contactor in certain embodiments, similar to the embodimentof FIG. 78. It can be seen in FIG. 80 that a circuit path lackingshort-circuit protection exists through the pre-charge circuit duringpre-charging operations when the high side breaker/relay 6502 is beingbypassed, unless protection is provided by a pre-charge fuse. In certainembodiments, a fuse in the pre-charge circuit (not shown) may beprovided to provide for short-circuit protection during the pre-chargeoperating condition, and/or the unprotected pre-charge operation may bean acceptable risk. In any of the embodiments depicted throughout thepresent disclosure, fuses may be included, potentially in-line with abreaker/relay 6502, depending upon the benefits sought from thebreaker/relay 6502 for the particular embodiment. In certainembodiments, an included fuse with a breaker/relay 6502 may beconfigured to activate at a very high current value that is expected tobe higher than the physical disconnection current of the breaker/relay6502, for example as a redundant protection for the circuit, and/or toprovide for a long-life fuse that is expected to last for a selectedperiod, such as the service life of the electric mobile application.

Referencing FIG. 81, an example power distribution management for amobile application is depicted, consistent with the embodiment depictedin FIG. 77. Power flow during pre-charge operations is depictedschematically in FIG. 81, with arrows showing the power flow path. Theoperations described in relation to FIG. 81 can be understood in thecontext of any of the embodiments described throughout the presentdisclosure. During pre-charge operations, the pre-charge contactor 7702is closed and the low side breaker/relay 6502 is closed, providing powerthrough the mobile circuit and through the pre-charge resistor 6406. Thepre-charge operation allows for capacitive elements of the mobilecircuit to be charged before the high side breaker/relay 6502 is closed.During pre-charge operations in the embodiment of FIG. 81, the low sidebreaker/relay 6502 provides for overcurrent protection of the circuit.After the pre-charge operation is complete, which may be determined inan open loop (e.g. using a timer) manner or in a closed loop (e.g.,detecting a voltage drop across the batter terminals, or detecting thecurrent through the circuit), the high side breaker/relay 6502 is closedand the pre-charge contactor 7702 may be opened.

Referencing FIG. 82, an example power distribution management for amobile application is depicted, consistent with the embodiment depictedin FIG. 77. Power flow during load powering operations is depicted inFIG. 82, with arrows showing the power flow path. The operationsdescribed in relation to FIG. 82 can be understood in the context of anyof the embodiments described throughout the present disclosure. Duringload powering operations, in the example the pre-charge contactor 7702is open, and power flows through the high side breaker/relay 6502 andthe low side breaker/relay 6502. The embodiment of FIG. 82 depicts atraction motor load being powered, but one or more auxiliary loads mayadditionally or alternatively be powered in a similar manner. Duringload powering operations, both the high side breaker/relay 6502 and thelow side breaker/relay 6502 provide overcurrent protection. In certainembodiments, the high side breaker/relay 6502 and the low sidebreaker/relay 6502 may have the same or distinct current ratings. Forexample, where one of the high side breaker/relay 6502 or low sidebreaker/relay 6502 are easier to service or less expensive, that one ofthe breaker/relays 6502 may have a lower overall current rating toprovide for a system where a predictable one of the breaker/relays 6502fails first. Additionally or alternatively, certain operations on thesystem may have a higher current rating—for example charging operationswhere the charging circuit is routed only through one of thebreaker/relays 6502 (e.g., the low side breaker/relay in the embodimentof FIG. 82), and thus one of the breaker/relays 6502 may have a highercurrent rating than the other. In certain embodiments, a breaker/relay6502 current rating may be reflected in the contact materials of themovable contact and the fixed contact, by a contact surface area of themovable contact and the fixed contact, by threshold settings for thecontrolled operations in response to detected current, by a number orarrangement of splitter plates, by splitter plate materials andgeometry, by the magnet strength and geometry of the permanent magnetsystem around the splitter plates, by the contact force of the contactforce spring, and/or by the breaker/relay design elements (e.g., contactsurface area and contact spring force) determining the physicaldisconnection current due to the Lorentz force on the contacts.

Referencing FIG. 83, an example power distribution management for amobile application is depicted, consistent with the embodiment depictedin FIG. 77. Power flow during regeneration operations is depicted inFIG. 83, with arrows showing the flow path. Regenerative operations frommotive loads are depicted, for example as might be experienced duringregenerative braking, but any regenerative operations from any loads inthe system are contemplated herein. During regeneration operations, thehigh side breaker/relay 6502 and the low side breaker/relay 6502 areclosed, and the pre-charge contactor 7702 may be open. Accordingly, boththe high side breaker/relay 6502 and the low side breaker/relay 6502provide overcurrent protection during regeneration operations of thesystem.

Referencing FIG. 84, an example power distribution management for amobile application is depicted, consistent with the embodiment depictedin FIG. 77. Power flow during charging operations is depicted in FIG.84, with arrows showing the flow path. Charging may be with an externalcharging device, and may include a high current quick charging operationwhich may provide for higher current operations than is associated witha rated power for the load(s). In the operations depicted in FIG. 84,the low side breaker/relay 6502 is closed, and contactors in thecharging circuit are closed, providing the power flow path as depicted.In certain embodiments, the high side breaker/relay 6502 and thepre-charge relay 7702 may be open, for example to isolate an inverter(not shown) from the circuit during charging operations. In certainembodiments, the high side breaker/relay 6502 may be closed, for examplewhere isolation of the inverter during charging operations is notrequired, and/or where rapid operation without a pre-charging cycleafter the charging may be desired. During charging operations, the lowside breaker/relay 6502 provides overcurrent protection in the exampleof FIG. 84.

Referencing FIG. 85, another cutaway schematic view of a breaker/relayis depicted. In the example of FIG. 85, circuit breaking and connectingcomponents are depicted on the breaker side 6820, and contactoroperation components are depicted on the relay side 6822. The depictedbreaker/relay is an example and depicts a single pole, single throwbreaker relay. Additionally or alternatively, a breaker/relay may be adual pole (e.g., operating two distinct circuits, a parallel path forone of the circuits to provide additional current capability, and/or onepole providing high-side coupling and the other pole providing low-sidecoupling). In certain embodiments, a breaker/relay having more than onepole can control the poles independently, or they may be operatedtogether utilizing the same armature. In certain embodiments, both poleshave arc diffusion protection provided by the same splitter plates, orby independent sets of splitter plates. In certain embodiments, bothpoles have arc diffusion protection provided by the same permanentmagnet system, or by independent permanent magnet systems.

Referencing FIG. 86, another example of a schematic logic diagram for abreaker/relay is depicted. The example of FIG. 86 includes an emergencyor auxiliary input 8602, which is processed by an input isolation 8604.The emergency or auxiliary input 8602 may replace or be in addition toany other auxiliary input, and provides for the capability of aparticular application to control operations of the breaker/relay for aselected response to any desired aspect of the system—including withoutlimitation, allowing for a disconnect assurance during service, duringan emergency, and/or according to any desired control logic.

Referencing FIG. 87, a detailed cutaway view of a contact portion of anexample breaker/relay is depicted. The contact portion of FIG. 87includes an example configuration for the contact surface of themoveable contact 6810 and the fixed contact 6812. The configuration ofthe contacts is a part of the system that contributes to the physicalopening force of the contacts, and can be configured with any shape orarea to provide the desired response to high currents occurring in theassociated circuit.

Referencing FIG. 88, an example breaker/relay is depicted with portionsof the housing removed for illustration. The example breaker/relayincludes two moveable contacts engaging two fixed contacts. In theexample of FIG. 88, the moveable contacts are coupled and operated bythe same armature 6814, with contact force provided by the contactspring 6804. In the example of FIG. 88, the contacts are electricallycoupled through a bus bar 8802. In the example, the bus bar 8802transitions directly between the contacts, and is not significantlyexposed to the current carrying portion of the bus bar including thefixed contacts. In certain embodiments, the bus bar 8802 can include atrajectory that exposes a portion of the bus bar 8802 into proximitywith the current carrying member of the fixed contacts, therebycontributing to the Lorentz force that provides the physical disconnectof the breaker/relay. In certain embodiments, both of the area of thebus bar 8802 exposed to the fixed contact current carrying portion, andthe proximity of the bus bar 8802 to the fixed contact current carryingportion are design elements that allow for configuration of the Lorentzforce response.

Referencing FIG. 89, an example power management arrangement for amobile application is depicted. The example of FIG. 89 includes abreaker/relay 6502 disposed on the high side of the power circuit, and apre-charge contactor, resistor, and fuse, coupled in parallel to thehigh side breaker/relay 6502. In the example of FIG. 89, thebreaker/relay 6502 is a dual pole breaker/relay 6502, for example toprovide additional current capability through the contacts for the powercircuit. In the example of FIG. 89, a controller 8902 is depicted thatperforms control functions for the breaker/relay 6502 and for the powermanagement arrangement. For example, the controller 8902 receives akeyswitch input, performs pre-charge operations, operates the closing ofthe breaker/relay, and responds to a high current event by opening thecontacts of the breaker/relay. In another example, the controller 8902performs shutdown operations of the power management arrangement, suchas opening the breaker/relay after the keyswitch is off, or in responseto an auxiliary, emergency, or other input requesting that power bedisconnected.

Further referencing FIG. 89, an example power distribution managementfor a mobile application is depicted schematically, which may beutilized in whole or part with any other systems or aspects of thepresent disclosure. An example power distribution management systemincludes a dual pole breaker/relay—the example of FIG. 89 includes adual pole breaker/relay (e.g., using one set of contacts per pole)having a single magnetic drive (e.g., a magnetic actuator). In certainembodiments, both contacts are mechanically linked such that they openor close together (e.g., operating as a dual pole single throwcontactor). In certain embodiments, the contactors may share one or morearc suppression aspects (e.g., splitter plates and/or permanent magnet),and/or may have individual arc suppression aspects. In certainembodiments, arc suppression aspects may be partially shared (e.g., somesplitter plates in proximity to both contacts) and/or partiallyindividual (e.g., some splitter plates in proximity to only one or theother of the contacts). In certain embodiments, various features of thecontactors may be shared and other features of the contactorsindividually supplied—such as control commands or actuation (e.g., adual pole, dual throw arrangement), arc suppression aspects, and/orhousings. The example of FIG. 89 additionally depicts a separatecontactor (e.g., the lower left of the three (3) depicted contacts)which is separately controllable to provide contact management for apre-charge circuit for the power distribution management system. Incertain embodiments, the pre-charge contactor may be integrated with thedual pole contacts—for example within a same housing as the dual polecontacts and/or with pre-charge coupling provided as one of the dualpole contacts. The example of FIG. 89 depicts a fuse on the pre-chargecircuit, and a further overall fuse on a battery low side. The presenceof fuses depicted is optional and non-limiting, and fuses may be presentin other locations, omitted, and/or replaced (e.g., by a breaker/relayas described throughout the present disclosure, and/or as a pole on adual pole or multi-pole breaker/relay). In certain embodiments, apre-charge circuit may be contained within a power distribution unitseparate from the breaker/relay and/or containing the breaker/relay, asa solid state pre-charge circuit, and/or as a mechanical/electricalcircuit positioned elsewhere in the system and/or within thebreaker/relay housing.

The electrical arrangement of poles in FIG. 89 is a schematic example,and not limiting to arrangements of the system for particularembodiments. In certain embodiments, each pole of the dual polebreaker/relay (and/or each pole or a subset of poles in a multi polebreaker/relay) may provide selectable electrical coupling for a samecircuit, for separate circuits, and/or for a selected circuit (e.g.,using controllable switches or connectors elsewhere in the system—notdepicted). In certain embodiments, the power distribution managementsystem further includes a high resolution current sensor, and/or currentsensing on more than one pole of the dual pole or multi polebreaker/relay. In certain embodiments, a controller is communicativelycoupled to the one or more high resolution current sensors, and utilizesthe one or more high resolution current sensors for any operationsdescribed throughout the present disclosure (e.g., to command one ormore of the contacts to an open position to avoid re-contact afteropening) and/or to communicate information determined from the currentsensor (e.g., the electrical current, or other information derivedtherefrom) to another controller in the system such as a vehiclecontroller. In certain embodiments, each contactor of the dual pole ormulti-pole breaker/relay includes an arrangement configured to open thecontact with a Lorentz force response due to high current through thecircuit of the contactor as described throughout the present disclosure.In certain embodiments, one contact has an arrangement to open with aLorentz force response, and the other contactor opens due to mechanicallinkage to the responding contactor. In certain embodiments, eachcontact has an arrangement to open with a Lorentz force response, forexample to provide circuit protection redundancy. In certainembodiments, each contact has an arrangement to open with a Lorentzforce response, where each contact has a separate configured thresholdfor opening response, and/or where each contact is separablycontrollable (e.g., with a separate magnetic actuator or othercontrolled actuator).

Referencing FIG. 90, a schematic depiction of an adaptive system using amulti-port power converter is depicted for hybrid vehicles. Theutilization of the terms multi-port, X port, and/or X-in-1 port indicatethat a power converter includes one or more ports that can servedistinct power loads and/or power sources with one or more varyingelectrical characteristics. A configurable power converter may have oneor more fixed ports, one or more configurable ports, or combinations ofthese. The example system 9000 includes a multi-port power converter9008, having a number of ports structured to connect to electricalsources and/or loads. The multi-port power converter 9008 in the exampleof FIG. 90 is coupled to four electrical loads/sources 9006 (9006 a-9006d), although any number of loads and/or sources may be connected to asdescribed throughout the present disclosure. In the example, eachload/source 9006 a to 9006 d has a distinct electrical characteristic,for example current type (e.g., AC, DC), frequency components (phase(s)and/or frequencies), and/or voltage. In certain embodiments, theload/source 9006 may have additional electrical characteristics orrequirements—for example a load which is a motor may have rise timeand/or response time requirements. The example multi-port powerconverter 9008 is able to configure the electrical characteristics tothe multi-port connections without a change to the hardware of themulti-port power converter 108, and further is able to supportconfiguration changes for the multi-port power converter 108 at variousselectable stages of manufacture, application selection, and/or in-useoperation as described throughout the present disclosure.

The example system 9000 includes a converter/inverter bank 9004. Theconverter/inverter bank 9004 includes a plurality of solid statecomponents that can be converted to various configurations of DC/DCconversion interfaces, and/or DC/AC conversion interfaces, to selectedones of the ports on the multi-port power converter 9008. An exampleconfiguration includes a plurality of half-bridge components havingconnectivity selected by a plurality of solid state switches in theconverter/inverter bank 9004. Accordingly, each of the ports on themulti-port power converter 9008 can be configured for the selected DC/DCand/or DC/AC interface according to the electrical load/sources 9006 inthe application. In certain embodiments, the half-bridge componentsinclude silicon carbide (SiC) half-bridges. SiC half-bridges, in certainembodiments, can operate at very high switching frequencies and highefficiencies with low electrical losses in the converter/invertercomponents.

The selection of the components in the converter/inverter bank 9004 maybe made according to the number of different load types to be supported.Accordingly, one of skill in the art can design a particularconverter/inverter bank 9004 to support a wide variety of contemplatedapplications, each of which can be supported by manipulating only solidstate switches and drive controls for the components of theconverter/inverter bank 9004, without changes to the hardware of themulti-port power converter 9008. For example, if a given class ofoff-road vehicles can be supported by 4 distinct DC voltage interactionsfor loads and power sources (e.g., a high voltage battery, a 12-Vcircuit, a 24-V circuit, and a 48-V circuit), and 2 distinct AC voltageinteractions (including potentially driving the load and acceptingregenerative inputs), then a configurable bank of components for theconverter/inverter bank 9004 and a sufficient number of ports arepackaged that will support the entire class of off-road vehicles withoutchanges to the hardware of the multi-port power converter 9008.Accordingly, a given application can be supported at a selected point inthe manufacturing cycle—either through calibration in a controller 9002at design time of the multi-port power converter 9008 (e.g., beforeintegration with an OEM), by an OEM assembling a vehicle and/ordriveline for the vehicle, and/or by a bodybuilder assembling a finalvehicle for a particular application. The controller 9002 may beaccessible by the use of a manufacturing tool, a service tool, or thelike, to configure the component bank 9004 in the multi-port powerconverter 9008, and/or to define the drive controls for the componentsin the component bank 9004 to meet the electrical characteristics of theloads/sources 9006 in the application.

In certain embodiments, a DC/DC conversion can be supported by ahalf-bridge having 4 MOSFET switches, and an AC/DC conversion can besupported by a half-bridge having 6 MOSFET switches. In certainembodiments, the half-bridges may be modular and can be combined asneeded to support a particular electrical input, output, or interface.Additionally or alternatively, H-bridge circuits, H-bridge circuitssupporting a three-phase output, or other components may be included inthe component bank 9004, depending upon the requirements for the classof applications to be supported by a particular multi-port powerconverter 9008.

The utilization of a multi-port power converter 9008 provides for anumber of benefits and features that allow for integration of a system9000 with a wide variety of applications without changes to thehardware. For example, the multi-port power converter 9008 allows forcentralization of power management on a given application, rather thanhaving a number of converters and/or inverters distributed throughoutthe vehicle or application. Accordingly, cooling requirements can bereduced, especially in the number of interfaces and connections forcooling to be supplied. Additionally, the electrical connections forpower conversion throughout the vehicle or application can bestandardized, and the number of connections reduced. Each connectiondrives a point of potential failure or environmental intrusion, andrequires specification, testing, and other integration requirements. Theuse of a multi-port power converter 9008 greatly simplifies integration,and allows for electrification and hybridization of many applications,such as off-road applications with a wide variety of load types, thathave not adopted electrification and/or hybridization in previouslyknown systems. Further, the ability of the multi-port power converter108 to configure port outputs and inputs allows for a wider variety ofloads on a particular system to be readily integrated into anelectrification and/or hybridization scheme, increasing the overallefficiency gains that can be achieved for the application, and enablinguse cases for electrification and hybridization that would otherwise beprohibitive to due design and integration challenges that do are notcommercially justifiable for complex designs and/or low volumeapplications. The ability to configure the multi-port power converter108 without changes to hardware, interfaces, and at selected points inthe manufacturing cycle additionally supports providing electrificationand/or hybridization for many applications where design control andintegration responsibilities may vary across the industry. Further, themulti-port power converter 9008 is configurable after initial use by anend user—for example to allow changes to a power rating or othersystemic change for the vehicle or application (which could beaccomplished remotely via an update to the controller 9002), changes inelectrical components on the vehicle or application that a customer mayimplement, and/or changes in electrical components made during service,remanufacture, or other post-use events.

Referencing FIG. 91, an example controller 9002 is depicted having anumber of circuits structured to functionally execute certain operationsand aspects of the controller 9002. The controller 9002 is depicted as asingle device positioned on the multi-port power converter 108, but thecontroller 9002 may be a distributed device having portions positionedon a vehicle controller, in a manufacturing or service tool, on a server(e.g., a cloud-based or internet accessible server), or combinations ofthese. In certain embodiments, aspects of the controller 9002 may beimplemented as computer readable instructions stored on a memory, aslogic circuits or other hardware devices structured to perform certainoperations of the controller 9002, and/or as sensors, datacommunications, electrical interfaces, or other aspects not depicted.The example controller 9002 includes a component bank configurationcircuit 9102 structured to interpret a port electrical interfacedescription 9104. The example of FIG. 91 depicts the port electricalinterface description 9104 communicated to the component bankconfiguration circuit 9102, but the port electrical interfacedescription 9104 may additionally or alternatively be stored in a memoryon or in communication with the controller 9002. The example controller9002 further includes a component bank implementation circuit 9106 thatprovides solid switch states 9108 in response to the port electricalinterface description 9104, where the component bank 9004 is responsiveto the solid switch states 9108, thereby setting up the connectionsbetween components on the component bank and the ports on the multi-portpower converter 9008 to provide the desired electrical interfaces,including varying DC voltage inputs/outputs and/or varying AC voltageinputs/outputs.

The example controller 9002 further includes a load/source drivedescription circuit 9110 structured to interpret source/load drivecharacteristics 9112. The source/load drive characteristics 9112 aredepicted as being communicated to the controller 9002, but mayadditionally or alternatively be stored in a memory on or incommunication with the controller 9002. The source/load drivecharacteristics 9112 provide for any characteristics for driving aparticular load, such as required phases, frequencies, rise timeparameters, and/or may include qualitative functions such as emergencyshutoff commands required to be supported or the like. The examplecontroller 9002 further includes a load/source drive implementationcircuit 9114 that provides a component driver configuration 9116. Thecomponent driver configuration 9116 may be, for example, the actual gatedriver controls utilized to drive the components of the component bank9004. In certain embodiments, components of a component bank 9004, suchas SiC solid state inverter/converter components, are provided with gatedriver controls from the manufacturer. In certain embodiments, thecomponent driver configuration 9116 provides interface commands andrequests that are passed to the manufacturer gate driver controls tomake appropriate requests for driving the components such that thesource/load drive characteristics 9112 are met. The actual arrangementand location of the gate driver controls is not limiting, and anyarrangement is contemplated herein and can be accommodated for aparticular system. It can be seen that the example controller 9002 ofFIG. 91 provides for rapid configuration of electrical characteristicsat the ports of a multi-port power converter 9008, including configureddriver controls that are motor agnostic (e.g., able to scale across arange of motor capabilities, and meet the mechanical requirements of themotor), without hardware changes to the multi-port power converter 9008.

Referencing FIG. 151, an example component bank configuration circuit9102 may be further structured to interpret a port configuration servicerequest value (e.g., port configuration request 15102), and wherein thecomponent bank implementation circuit 9106 further provides the solidswitch states 9108 in response to the port configuration service requestvalue 15102. The component bank configuration circuit 9102 may befurther structured to interpret a port configuration definition value15104, and wherein the component bank implementation circuit 9106further provides the solid switch states in response to the portconfiguration definition value 15104. Accordingly, the controller 9002for a system may be responsive to configuration requests and/orconfiguration definitions for events such as: service, integration,manufacture, remanufacture, upgrades, upfits, and/or changes to anapplication of the of the system.

Referencing FIG. 92, an example system 9200 is depicted including amulti-port power converter 9008. The example system 9200 may be anactual contemplated system—for example a serial hybrid vehicle having aplurality of DC loads, a traction motor, an internal combustion enginewith a motor/generator interface to the multi-port power converter 9008,and a high voltage battery. In certain embodiments, a system 9200 may bea representative system for a class of applications—for exampleincluding a sufficient number of interfaces and loads such that, if theexample system 9200 can be sufficiently supported, then a multi-portpower converter 9008 to support that system would be capable to supportan entire class of applications without hardware changes. In certainembodiments, a multi-port power converter 9008 may be designed in morethan one version, for example to support a similar number of electricalinterfaces and number of types of interfaces, but have distinctcomponents such as to support a high voltage level in one version, and alower voltage level in another version. It can be seen that an examplesystem 9200 will still be useful as an actual system to be built thatcan be repeated with few hardware changes to support similar classes ofapplications, or as a representative system where a limited number ofselected hardware changes in the multi-port power converter 9008 cansupport a large class of applications.

The example system 9200 includes an internal combustion engine 9202. Theinternal combustion engine 9202 represents any prime mover or powersource, and may additionally or alternatively include a grid powerconnector, fuel cell, or other device. In certain embodiments, theinternal combustion engine 9202 provides power to the multi-port powerconverter 9008 during certain operating conditions, and can accept powerfrom the multi-port power converter 9008 during other operatingconditions. The example system 9200 further includes a motor/generator9204 that electrically interfaces the internal combustion engine 9202with the multi-port power converter 9008, and is typically (but may notbe) an AC device having a relatively high power rating (e.g., 80 hp inthe example). Where necessary for the application or the class ofapplications under consideration, the motor/generator 9204 is capable totransfer power in either direction—accepting power from the internalcombustion engine 9202 and/or returning power to the internal combustionengine 9202. The example depicts the multi-port power converter 9008having a 3-wire interface to the motor/generator 9204, although anyinterface may be supported.

The example system 9200 further includes a traction motor 9206, whichmay be an AC motor and/or motor/generator, and is depicted with a 3-wireinterface to the multi-port power converter 9008. In the example of FIG.92, the traction motor 9206 drives a transmission 9208, but the tractionmotor 9206 may drive any traction device, for example providing motivepower to the vehicle or other device. The transmission 9208 representsconceptually any primary powered component for the system 9200, and mayadditionally or alternatively be a pump or other high power requirementdevice in the system. Additionally, the transmission 9208 may not bepresent, and the traction motor 9206 may interface directly with theprimary powered component. The example of FIG. 92 is a “serial hybrid”example, where the prime mover 9202 and the primary load 9208 areelectrically separated, although a given system 9200 (whether an actualdesigned system or a representative system for designing in appropriatecapability to a multi-port power converter 9008) may be a “parallelhybrid” (e.g., the prime mover 9202 is capable to fully or partiallydrive the primary load 9208 directly, at least intermittently), a fullyelectrical system (e.g., where the prime mover 9202 is not present,and/or is only utilized as a backup power supply), and/or any otherarrangement (e.g., where shaft power from some other source is providedin addition to or at the position of the prime mover 9202 depicted inFIG. 92). In certain embodiments, an arrangement such as the serialhybrid arrangement of FIG. 92 is contemplated for a system or arepresentative system, because the serial hybrid arrangement provides anumber of interface requirements to the multi-port power converter 9008that are sufficient to also support other systems (e.g., serial hybridor fully electric), and accordingly a multi-port power converter 9008capable to support a serial hybrid arrangement is capable to support alarge class of systems, vehicles, and applications without hardwarechanges to the multi-port power converter 9008.

The example system 9200 of FIG. 92 further depicts a number of DC loadsand sources. In the example of FIG. 92, a high voltage DC interface (650V, in the example) couples to a high voltage battery 9212 and a mainpump motor 9210 (e.g., supporting a hydraulic pump for an off-roadvehicle having a large hydraulic system). The main pump motor 9210 andthe high voltage battery 9212 are depicted as coupled to the same 650Vcircuit, although a large DC load (e.g., the main pump motor 9210) and ahigh voltage battery 9212 need not be at the same voltage on aparticular system. In the example of FIG. 92, the main pump motor 9210is also rated at 80 hp—which in the example allows for themotor/generator 9204 to fully support either traction loads or main pumploads, which may be a contemplated arrangement for a particular systemor a contemplated system to support a class of applications. However, incertain embodiments, a main DC load and/or the traction load may differ,and the motor/generator 9204 may support only a highest one of theavailable loads, all of the available loads simultaneously, and/orsupport some other load value (e.g., an expected average load over theoperating cycle of the application, a load value that is expected torely upon net battery 9212 discharging during some operating periods, orthe like). In certain embodiments, the motor/generator 9204 may not bepresent, or may have a load capability unrelated to the DC and/ortraction loads on the application.

In the example of FIG. 92, a 12 V DC interface 9214 is depicted, whichin the example of FIG. 92 drives an actuator to operate a load 9216using the hydraulic pressure from the main pump motor 9210. In theexample, the 12 V DC interface 9214 is coupled to the load 9216 allowingfor both actuation and regenerative recovery from the load 9216. Thedirectional operation of power on the 12 V DC interface 9214 drives aconfiguration of the components in the multi-port power converter 9008to allow for both powering the 12 V DC interface 9214 and recoveringenergy from the 12 V DC interface 9214, and can be utilized for any 12 VDC operations (e.g., vehicle accessories, low power devices, etc.). Incertain embodiments, power recovered on the 12 V DC interface 9214 maybe returned to the high voltage battery 9212, provided to a low voltagebattery interface (not shown), and/or used for other loads in thesystem.

In the example of FIG. 92, a 48 V DC interface 9218 is depicted, whichin the example of FIG. 92 drives an actuator to operate a second load9220 using the hydraulic pressure from the main pump motor 9210. In theexample, the 48 V DC interface 9218 is coupled to the load 9220 allowingfor both actuation and regenerative recovery from the load 9220. Thedirectional operation of power on the 48 V DC interface 9218 drives aconfiguration of the components in the multi-port power converter 9008to allow for both powering the 48 V DC interface 9218 and recoveringenergy from the 48 V DC interface 9218, and can be utilized for any 48 VDC operations (e.g., vehicle accessories, refrigeration, PTO devices,etc.). In certain embodiments, power recovered on the 48 V DC interface9218 may be returned to the high voltage battery 9212, provided to a lowvoltage battery interface (not shown), and/or used for other loads inthe system.

It can be seen that a system 9200 such as depicted in FIG. 92 canreadily provide for integration and support to a large number ofapplications with minimal changes for design of the interface to themulti-port power converter 9008, and with no changes to hardware orselected versions from a small number of hardware versions of themulti-port power converter 9008. Certain application differences can besupported without changes—for example the types of loads on a 12 Vinterface 9214 can be changed without any hardware or even calibrationchanges in the controller 9002. Certain application differences can besupported with only calibration changes in the controller 9002—forexample switching a 12 V interface 9214 to a 24 V interface (or someother value). Certain application differences can be supported with onlya minor hardware version change—for example switching a high voltage DCfrom 650 V to 900 V may require only a different version of themulti-port power converter 9008 having a more capable SiC component thatcan interface with the higher voltage. It can also be seen that manyapplication changes can be accommodated at selected points in themanufacturing cycle, including at design time of the multi-port powerconverter 9008, at a OEM phase (e.g., integrating the multi-port powerconverter 9008 with a selected driveline), at a bodybuilder phase (e.g.,integrating a particular vehicle or specific loads with the multi-portpower converter 9008), and/or after the application has been in use(e.g., changing or upgrading an electrical system of the vehicle,changing a power rating, performing a remanufacture or upgrade of theapplication, and/or changing a basic use scenario or duty cycle for thesystem, vehicle, or application). Additionally or alternatively,versions of the multi-port power converter 9008 may be configured fordifferent applications that are electrically similar (e.g., the same orsimilar number of distinct voltages, electrical types, and power ratingsrequired) but have different certifications or regulations applicable,where the configuration of the multi-port power converter 9008 isotherwise similar, but the components, diagnostics, or other aspects ofthe multi-port power converter 9008 are configured in each version forthe different certifications, regulations, or other requirements of eachclass of applications. For example, an electrically similar on-road andoff-road application may have distinct requirements for certificationsand/or a different regulatory requirement for components on themulti-port power converter 9008.

Referencing FIG. 107, an example X-port converter 9008 is depicted,which is similar to the embodiment depicted in FIG. 92. In the exampleof FIG. 107, the X-port converter 9008 further includes fuses/contactors10702, which may be provided on circuits to be used for powerconnections, and/or may be configured to be coupled into selectedcircuits by solid state switches. The example X-port converter 9008further includes a solid state switch bank 10706 positioned between thepower electronics 9222, 9224 and coupling ports on the housing of theX-port converter 10706, allowing for configured power electronics,fuses, and/or contactors to be directed into the circuit associated withany selected port. The example X-port converter 9008 further includes acontroller 10704, which may be responsive to commands to configure theconverter, to interrogate electrical sources and loads to determinetheir electrical characteristics, and/or to determine power exchangeparameters (e.g., regenerative loads received, etc.) and improve theefficiency of operations of the converter to support the loads andsources. Referencing FIG. 108, an example X-port converter 9008 isdepicted, which is similar to the embodiment depicted in FIG. 107. Inthe example of FIG. 108, the port bank 10806 may not include a solidstate switch bank. In the example of FIG. 108, ports of the converter9008 have configurable electrical characteristics, but may have lessflexibility than the example of FIG. 107. For example, a given port maybe a dedicated AC port in the example of FIG. 108, with configurablevoltage, frequency, and phase ratings, where in the example of FIG. 107a given port may be switchable between AC and DC. The example converter9008 of FIG. 108 additionally includes a coolant port (e.g., a coolantinlet coupling and a coolant outlet coupling) for coupling to a coolantsource 10802 (e.g., the primary cooling system for an electric mobileapplication). In the example, the coolant coupling 10804 provides for aconsistent cooling interface to all power electronics. The coolantcoupling 10804 may be present in any embodiment of the converter 9008.

It can be seen that the systems described herein provide for a highmachine level efficiency for systems, vehicles, and applications at alower cost than previously known systems. Additionally, the ease andselectability of integration of the systems herein enable the use ofhybrid, fully electric, and/or regenerative systems for applications notpreviously available due to the difficulty of integration and/or lowvolumes of such applications that prohibit development of a hybrid,fully electric, and/or regenerative system for such applications. Thesystems described herein are scalable to different power ratings andvoltage levels on both DC and AC portions of the system. Additionally,energy recovery systems for a wide variety of loads, such as forhydraulic loads, motive loads, PTO loads, pneumatic loads, and/or anyother type of load that is capable of interfacing with an electricalsystem of any type can readily be supported, including as a class ofapplications that are supported without hardware changes to a multi-portpower converter 9008. Additionally, the systems herein are agnostic tothe motor and/or motor/generator requirements for a particularapplication, and can support any type of electrical interface withouthardware changes and/or with only minimal calibration changes in acontroller 9002 at a selected point in a manufacturing cycle, andincluding post-use changes such as for upgrades, remanufacture, service,and/or maintenance. The systems herein provide for a ready interface andintegration with prime movers or power sources, traction drive, andsystem loads. Both load support and energy recovery are readilysupported on any interface of the multi-port power converter 9008. Awide variety of previously known applications do not utilizehybridization and/or electrification due to the integration,certification, and/or number of diverse loads on those systems thatprohibit reasonable integration of hybrid and/or electrified actuationand energy recovery of various loads—such as pumps, cranes, heavy-dutywork vehicles, wheel loaders, aerial lift trucks, and tractors. Thesystems herein provide for ease of design and integration with any suchapplications, including the support of classes of applications with aconfigurable multi-port power converter 9008 able to accommodate theclasses of applications without hardware changes, and/or using a smallselected number of hardware versions. The use of SiC components in amulti-port power converter 9008 can provide 5-10% power conversionefficiency improvement in electrical conversion, and the addition ofenergy recovery and prime mover optimization (e.g., operating a primemover in efficient operating regions a greater percentage of the timeduring operations) can result in overall machine level efficiency gainsof >50% for applications where previously known systems do not enableadoption of hybridization and/or electrification of loads and energyrecovery. The systems herein provide for ready adoption of hybridizationand electrification of loads on an application where previously knownsystems are not feasible for integration, and provides for selectedengagement of the design of the multi-port power converter 9008 in themanufacturing and supply chain to further improve ease of integrationand enable adoption for applications where previously known systems arenot viable.

Referencing FIG. 93, an example breaker/relay 9302 is schematicallydepicted in a context 9300. The example context 9300 includes aregulatory interface 9304, for example including legal or industryregulations, policies, or other enforceable frameworks for which thebreaker/relay 9302 is responsible to maintain certain performancecharacteristics. The example regulatory interface 9304 may be physicallymanifested during run-time operations of an application having thebreaker/relay 9302 thereon—for example as a network communication,calibrated value for a response, selection of a sizing of a component ofthe breaker/relay 9302 or the like, and/or the regulatory interface 9304may represent one or more design time considerations made during theselection, installation, repair, maintenance, and/or replacement of abreaker/relay 9302 that are not physically manifested during run-timeoperations of the application having the breaker/relay 9302 thereon.

The example context 9300 further includes a command and/or controlinterface 9306, which may include signals, voltages, electricalcouplings, and/or network couplings over which commanded functions(e.g., connector open or closed commands) are received by thebreaker/relay 9302. In certain embodiments, the breaker/relay 9302includes only electromechanical components—for example where thebreaker/relay 9302 does not include a microprocessor, controller,printed circuit board, or other “intelligent” features. In certainembodiments, the breaker/relay 9302 includes some functions controllerlocally on the breaker/relay 9302, and other functions controllerelsewhere on an application having the breaker/relay 9302 thereon—forexample on a battery management system controller, vehicle controller,power electronics controller, and/or having aspects distributed acrossone or more controllers. In certain embodiments, certain command orcontrol aspects are provided as physical or electrical commands, andother command or control aspects are provided as communicative elements(e.g., datalink or network commands) and/or as intelligent aspects ofthe breaker/relay 9302 determined in accordance with programmed logic inresponse to detected or otherwise determined parameters during run-timeoperations.

The example context 9300 further includes an environmental interface9308, such as the vibration, temperature events, shock, and otherenvironmental parameters experienced by the breaker/relay 9302. Aspectsof the environmental interface 9308 may be physically manifested in thebreaker/relay 9302, for example through material design selections,sizing and location of parts, connector selections, active or passivecooling selections, and the like. Additionally or alternatively, theplanned or experienced duty cycle, power throughput, or the like may bea part of the environmental interface 9308 of the breaker/relay 9302.

The example context 9300 further includes a high voltage interface 9310,for example a coupling to the high voltage battery of a system, tosystem loads, to a charger, or the like. In certain embodiments, thehigh voltage interface 9310 is physically manifested on thebreaker/relay 9302, for example with voltage ratings, sizes ofcomponents, ratings of current sensors (where present), materialselections, and the like. Any example features of a breaker/relay asdescribed throughout the present disclosure may be included herein foran example breaker/relay 9302, including without limitation arcextinguishing features, contactor design elements, connector contactforce affecting aspects, and the like. Any aspects of the context 9300may be included or omitted, and the described aspects of the context9300 are not limiting to the contemplated context 9300 of a particularbreaker/relay 9302. Additionally, it will be understood that theorganization of context 9300 aspects is an example for clarity ofdescription, but that particular aspects 9304, 9306, 9308, 9310 may beomitted, separated, and/or present on other aspects 9304, 9306, 9308,9310 in certain embodiments. For example, a voltage limit, time limitfor response, etc. may be understood to originate from a regulatoryinterface 9304 in one embodiment, from a command/control interface 9306in another embodiment, and from both interfaces 9304, 9306 in yetanother embodiment.

Referencing FIG. 94, an example breaker/relay architecture 9400 isdepicted. The example breaker/relay 9302 includes all electronic controlfunctions positioned away from the breaker/relay 9302, with onlyelectro-mechanical hardware remaining on the breaker/relay 9302. Theexample breaker/relay 9302 includes a contactor 9402 movably operated bya coil 9404, for example a high voltage contactor that is normally openor normally closed, and wherein power to the coil 9404 provides foropening or closing force to the contactor 9402. In certain embodiments,the contactor 9402 is normally open, and power to the coil 9404 closesthe contactor 9402. The example architecture 9400 further includes ahigh voltage circuit 9406 switched by the contactor 9402, and a pair ofinput signals—for example an A input 9408 and a B input 9410, althoughany number and type of input signal is contemplated herein. An examplesystem is depicted in FIG. 96 showing example operations of theElectronics to control the example breaker/relay 9302 (Magnetic drive2302 in the depiction of FIG. 96). The example architecture 9400 furtherincludes an external controller 9412, for example a battery managementcontroller, vehicle controller, or other controller present on anapplication, the external controller 9412 including the Electronicsportion and a Management portion. For the example architecture 9400, theElectronics portion schematically depicts a controller configured tomanage direct opening and closing control of the breaker/relay 9302 andto communicate diagnostic information about the breaker/relay 9302. TheManagement portion schematically depicts the sourcing of externalcommands to the breaker/relay 9302, for example to command thebreaker/relay 9302 on or off, to implement an over-current shutdown,and/or to implement an auxiliary or safety shutdown (e.g., a crashsignal, service event signal, or the like). The Electronics andManagement portions are depicted in an arrangement for clarity ofdescription, but it is understood that aspects of the Electronics andManagement portions may be distributed throughout a system, and/orportions of the Electronics may be positioned on a breaker/relay 9302.

Referencing FIG. 95, an example system 9500 is depicted showing certainvoltage, amperage, and time-based values for an example system. Theexample system 9500 includes a switch on signal having certainelectrical characteristics and a hold signal having certain electricalcharacteristics, which are non-limiting examples. The example system9500 is consistent with certain embodiments of the architecture 9400depicted in FIG. 94. An example breaker/relay consistent with certainembodiments of the system of FIG. 95 is responsive to an 8.2V switch-onvoltage, a holding voltage of 1.5V, and includes a 3 Ohm resistance inthe actuating coil.

Referencing FIG. 96, operations of an example Electronics portion of anarchitecture 9400 such as that depicted in FIG. 94 are shown forpurposes of illustration. It will be understood that components of asystem such as in FIG. 96 may be implemented in hardware, software,logic circuits, and/or may be combined or distributed about a system.The example Electronics include a Switch On response, with a 12 Vcontrol voltage applied to the module. The actual drive coil of thebreaker/relay can be switched to the control voltage via a deenergizingcircuit and driver. The switch-on driver 9702 is controlled atapproximately 65% of the minimum nominal voltage (e.g., rated value <70%or 8.2 V) for 100 ms. The timing, voltage, and switching logic of SwitchOn operations are non-limiting examples. During Switch On operations,the drive coil is energized with the pull-in current, so that the drivecan switch on.

An example Electronics includes a Regulation response. An exampleRegulation response includes linearly regulating the voltages during theSwitch On process, for example using a control circuit (Regulation) andLinkage for the duration of the switch-on process (e.g., 100 ms) therebyapplying a selected actuating voltage to the drive coil.

An example Electronics includes a Hold response. The example Holdresponse includes disabling the Driver after the Switch-on time period,and providing the drive coil with a hold signal (e.g., 1.5 V) thatremains on constantly, and/or constantly with diagnostic interruptions(e.g., see schematic voltage graph 9708).

In certain embodiments, the deenergizing transistor is checked atselected intervals (e.g., depending upon the Fault Tolerant TimeInterval, a regulatory or policy interval, and/or an interval ofinterest). If the deenergizing transistor is defective (e.g., if it ispermanently conductive), the breaker/relay will be reliant on turningoff the 1.5V supply to de-energize the magnetic drive. While the systemcan still be turned off, the operations with a defective deenergizingrelay may be slower than anticipated, and/or too slow for thebreaker/relay to be compliant. In certain embodiments, the frequentblanking pulses (or diagnostic interruptions) lead to cut-off voltagepeaks at the coil connection (Freewheeling level, approx. 180V in theexample system). If the voltage peaks remain off, the deenergizingtransistor can be diagnosed as defective. In certain embodiments, theblanking pulses are kept short, thereby keeping the energy in thefreewheeling circuit low, reducing waste energy and heating, and alsokeeping the holding energy low to reduce noise emissions. In certainembodiments, 100 micro-second blanking pulses are sufficient. In certainembodiments, faster or slower blanking pulses may be utilized. Incertain embodiments, diagnostics of the deenergizing relay and/or systemresponses (e.g., a more conservative shut-off to account for slowerresponse) may be utilized, in the Electronics, the Management, orelsewhere in the system.

An example Electronics includes a Switch-off and/or deenergizingresponse. In the example, turning off the 1.5V holding voltagedeactivates the deenergizing circuit above a trigger voltage of about4.5V (nominal <50%*Urated=6V).

Certain further example embodiments of systems having a breaker/relaydevice incorporated therein are set forth following. Any one or moreaspects of the following systems may be included within any othersystems or portions of a system described throughout the presentdisclosure. Any one or more aspects of the following systems may beutilized in performing any procedure, operations, or methods herein.

Referencing FIG. 97, an example system 9702 includes a breaker/relaydevice having a pre-charge circuit, a current sensor, and a pyro-switchdevice positioned within a single housing. Referencing FIG. 98, thesystem 9207 is depicted with a transparent housing for convenience ofillustration. The example system 9702 includes the breaker/relay 6502, acurrent sensor 6706, a pre-charge fuse 6406, and a pre-charge contactor6408 positioned within the housing and arranged to electricallyinterface with a power circuit, such as a mobile power circuit for amobile electric application.

In certain embodiments, the breaker/relay device includes any combinedbreaking and contacting device, for example as described throughout thepresent disclosure. In certain embodiments, the breaker/relay deviceincludes a single contact (e.g., as compared with a dual contactembodiment). In certain embodiments, the breaker/relay device includestwo contacts operated utilizing a single actuator. In certainembodiments, the system includes a fuse, which in the embodiment of FIG.98 is depicted as a pyro-switch 9802 (or pyro-fuse), such as apyrotechnically activated fuse (e.g., a fuse separated at a selectedtime by operating a small explosive device to break the circuit). Incertain embodiments, the pyro-switch is operated on a circuit in linewith one leg of the circuits controlled by the breaker/relay device6502, for example to provide pyro-switch protection for a high side or alow side of a circuit. For convenience of illustration, the pre-chargecircuit wiring is not depicted. The pre-charge circuit may be wired inparallel with a contactor of the breaker/relay 6502, and/or in parallelwith the pyro-switch 9802. Referencing FIG. 99, a top schematic view ofthe system 9702 is depicted, showing an illustrative arrangement of thecomponents in the system. The example system 9702 includes high voltageconnections 9902, such as a low and high side connection to a powersource (e.g., a high voltage battery) and a low and high side connectionto a load (e.g., a motor providing motive power). Referencing FIG. 100,a side schematic view of the system is depicted, from an end having thepyro-switch 9802 and the pre-charge fuse 6406.

In certain embodiments, the system 6702 (e.g., a “breaker/relay PDU”)has a mass that does not exceed 5 kg, and/or does not exceed 1.5 kg. Incertain embodiments, a dimension of the breaker/relay PDU is smallerthan one or more of: a 600 mm length, a 140 mm width, and/or a 110 mmheight. In certain embodiments, a dimension of the breaker/relay PDU issmaller than one or more of: a 160 mm length, a 135 mm width, and/or a105 mm height. In certain embodiments, the breaker/relay PDU is capableto support operating at 300 A or greater continuous current flow. Incertain embodiments, the breaker/relay PDU is capable to interrupt 1100A and/or over 400 V without assistance. In certain embodiments,breaker/relay PDU is capable to interrupt 8,000 A and/or over 400 V. Incertain embodiments, the breaker/relay PDU is capable to passivelyinterrupt a short circuit condition (e.g., no outside control signal orcommunication required), and/or is further capable to actively interruptother operating conditions (e.g., an active trigger command for anyreason). In certain embodiments, the pyro-switch 9802 is on the negativeleg of the overall circuit, although the pyro-switch may be anywhere itis desirable. In certain embodiments, the pyro-switch is activelycontrolled with a trigger to command an interrupt. In certainembodiments, the breaker/relay, the pyro-switch 9802, and/or both may beactively commanded to interrupt the circuit. In certain embodiments, thebreaker/relay PDU is capable to support dual amp ratings, such as 90 Aand 1000 A (non-limiting example).

Referencing FIG. 101, an example system 10100 includes a power circuitprotection arrangement for a high-voltage load, such as for a motivepower circuit for a mobile application. The example system 10100includes a breaker/relay PDU 10102, where the breaker/relay 10106 isdisposed in the high-side of the motive power circuit. The examplesystem 10100 includes a pre-charge circuit 10104, including a pre-chargeresistor and a pre-charge contactor, positioned within the housing ofthe breaker/relay PDU 10102. The example system further includes acurrent sensor 6706 and a pyro-switch 9802 positioned within the housingof the breaker/relay PDU 10102. The system includes the breaker/relayPDU 10102 interfaced with a high-voltage battery 10110 on a first side,and with a high-voltage load 10108 on a second side.

Referencing FIG. 102, an oblique view of a system 10200 having a dualpole breaker/relay 10302 is depicted, with a coupled current sensor 6706connected thereto. The example current sensor 6706 is shown with aconnector 10202 for communicative coupling to a controller. ReferencingFIG. 103, a top view of the system 10200 is depicted having a partiallytransparent top side of a housing of the system 10200. Example positionsfor the pre-charge fuse 6406 and pre-charge connector 6408 are shown,and coupling locations for a high voltage battery (HV battery + and −)and for a high voltage load (HV load + and −) are illustrated.Referencing FIG. 104, a system 10200 consistent with the system of FIG.103 is depicted, with the top side of the housing of the system normallypositioned. Referencing FIG. 105, an example breaker/relay PDU isdepicted showing high voltage bus bar couplings 10502, 10504, 10506,10508 to the breaker/relay PDU. In the example of FIG. 105, connection10508 is the battery low side, connection 10506 is the battery highside, connection 10502 is the high voltage load high side, andconnection 10504 is the high voltage low side. However, any arrangementof high voltage source and load connections is contemplated herein.

Referencing FIG. 106, an example system 10600 includes a power circuitprotection arrangement for a high-voltage load, such as for a motivepower circuit for a mobile application. The example system 10600includes a dual pole breaker/relay PDU 10602, where the breaker/relay10606 includes a first pole disposed on the high-side of the motivepower circuit, and a second pole disposed on the low-side of the motivepower circuit. The example system 10600 includes a pre-charge circuit10104, including a pre-charge resistor and a pre-charge contactor,positioned within the housing of the breaker/relay PDU 10602. Theexample system further includes a current sensor 6706. The examplesystem 10600 does not include a fuse or a pyro-switch, although a fuseor pyro-switch may be present in certain embodiments. The systemincludes the breaker/relay PDU 10602 interfaced with a high-voltagebattery 10110 on a first side, and with a high-voltage load 10108 on asecond side.

The example dual-pole breaker/relay device includes separatebreaker/relay contactors responsive to active and passive interruptionoperations, having arc suppression, and/or one or more of the poleshaving a current sensor. In certain embodiments, each pole is disposedin a high side or a low side circuit of a system. In certainembodiments, one or more of the poles includes an integrated prechargecircuit in parallel therewith.

It can be seen that the example single-pole and dual-pole breaker/relaydevices provide for highly capable interruption systems, as well assystems with high flexibility on the capability. Additionally, thesystems have resettable interruption (with the breaker/relay), and theintegration as depicted significantly reduces the footprint frompreviously known systems.

Example embodiments include a high voltage electric vehicle batterypower distribution system architecture that includes a breaker/relaywith a precharge circuit integrated in the same housing. These twoelements distribute power from one side of the battery. In addition tothese two elements, the housing also contains a current sensor and pyrodisconnect (e.g., pyro-switch), that are in series with each other onthe opposite side of the battery.

High voltage batteries in mobile applications contain a large amount ofenergy, making it desirable that the rest of the vehicle and operatorsto be protected in the event of overload, short circuit, or emergencyconditions. Previously known systems include a contactor and a fuse onthe high side of the battery, a precharge circuit in parallel of thehigh side contactor, and a contactor and current sensor on the low sideof the battery. Certain example systems of the present disclosures haveat least one or more of the following benefits over previously knownsystems: Efficiency (e.g., power transfer, losses, reduced coolingrequirements) by reducing the number of contactor poles from two to one;providing active and passive protection in overcurrent, short circuit,or emergency events, because the breaker/relay or pyro can both beactively triggered; additional break protection in an overload or shortcircuit event, such as physical breaking operations that do not relyupon an active and properly operating controller; size and weightadvantages, because of the shared housing and combined componentfootprint being smaller; and the like.

Referencing FIG. 109A, a top view and in FIG. 109B a side view (right)of an example embodiment of an integrated inverter assembly 10900 isschematically depicted. The example of FIGS. 109A, 109B includes a highvoltage DC battery coupling 10902 and a vehicle (or mobile application)coupling 10904. The vehicle coupling 10904 provides for datacommunications, keyswitch state, sensor communications, and/or any otherdesired coupling aspects. Referencing FIGS. 109A, 109B, a batteryconnector 10902 and vehicle connector 10904 are provided, which may beany type of connector known in the art and selected for the particularapplication. An example battery connector 10902 includes a RosenbergerHPK series connector, however any battery connector may be utilized. Anexample vehicle connector 10904 includes a Yazaki connector part number7282885330, however any vehicle connector may be utilized. In theexample of FIGS. 109A, 109B the main cover is visible, which may be onthe vertically upper portion of the integrated inverter assembly 10900as installed on a vehicle or mobile application, although otherorientations of the integrated inverter assembly 10900 are contemplatedin certain embodiments of the present disclosure. In the example ofFIGS. 109A, 109B, a harness 10906 is depicted, which provides aconnection for a motor temperature and/or position sensor. The harness10906 may be shielded as determined according to the specific EMIenvironment, sensor characteristics, and/or communication mechanismbetween the sensor(s) and the integrated inverter assembly 10900. In theside view of FIG. 109B, the base (or back cover) can be seen.

Referencing FIG. 110, an underside view of the main cover of theintegrated inverter assembly 10900 is schematically depicted, withcertain aspects removed for clarity of the description. The integratedinverter assembly 10900 includes coolant inlet and outlet connections11002, which may be blind connections, and/or which may be sized toaccommodate an SAEJ2044 Quick Connect Coupling. The coolant connectionsprovide for coolant flow through one or more coolant channels, asdescribed in the present disclosure. In the example of FIG. 110, themain cover is coupled to the back cover using a cure-in-place-gasket.

Referencing FIG. 111, the underside view of the main cover of theintegrated inverter assembly 10900 is schematically depicted, withcertain aspects of the electronics packaging of the integrated inverterassembly 10900 included for reference. Referencing FIG. 112, motorconnections 11202 configured for a 3-phase high voltage motorconnection, for example as blades that interface with the motorconnector 10906 of FIG. 111. The example of FIG. 112 depicts a printedcircuit board (PCB) where the gate drivers for the inverter are mounted,as well as a current sensor corresponding to each phase of the gatedrivers. The example of FIG. 112 depicts a second PCB (partiallyobscured by the DC link capacitor 11206) for control of the inverter,including interfaces with the vehicle, power control operations,diagnostics, and the like. The DC link capacitor 11206 provides forcoupling between the DC high voltage system (e.g., the battery) and thegate drivers. In certain embodiments, the DC link capacitor 11206 mayinclude certain power conditioning aspects, such as a capacitor, a busbar, and/or a choke. Referencing FIG. 113, an embodiment having acoolant channel 11304 is depicted, with connector 11306 for an inverterdrive of the inverter assembly 10900.

Referencing FIG. 113, a top surface 11402 of a coolant channel (theupper coolant channel in the example of FIG. 113) is depicted. The gatedrivers (e.g., IGBTs) are mounted in thermal contact with the coolantchannel, such that coolant flowing through the coolant channel thermallycommunicates with the inverter power electronics.

Referencing FIG. 114, an underside (relative to FIG. 113) of the maincover is depicted to show aspects of the coolant channels 11402, withthe lower coolant channel being depicted in FIG. 114. The coolantchannel includes heat transfer features (pins, in the example of FIG.114) to provide the desired heat transfer environment between thecoolant flowing in the channel and cooled components of the integratedinverter assembly 10900. Two of the holes defined in the lower coolantchannel of FIG. 114 provide inlet and outlet communication to coolantinto the inverter. Two of the holes defined in the lower coolant channelof FIG. 114 provide fluid communication between an upper coolant channeland a lower coolant channel. Referencing FIG. 115, an examplerelationship between the upper coolant channel 11506 and the lowercoolant channel 11504 is depicted. In the example of FIG. 115, each ofthe coolant channels includes heat transfer features such as pins. Theutilization of two parallel coolant channels provides for increased heattransfer capacity and greater ease in communication with all cooledcomponents within a compact integrated package. The description ofcoolant channels as “upper” and “lower” is for convenience and clarityof description to identify the separate channels. The actual verticalpositioning of channels may vary with the specific design of theintegrated inverter assembly, and the orientation of the integratedinverter assembly as installed. FIG. 115 additionally depicts anexternal coolant coupling port 11204, having a baffled stem 11502 in theexample of FIG. 115.

Referencing FIG. 116, an assembly example for coupling the coolantchannels with the main cover is depicted. In the example, a coolantchannel separating body 11604 (having the lower coolant channel on theunderside, and the upper coolant channel on the upper side) is assembledwith a lower coolant channel cover 13102 (e.g., the portion of thecoolant channel visible in FIG. 109A) and the main cover body. Incertain embodiments, the assembly of FIG. 116 is formed usingfriction-stir welding (FSW), which is a low cost process that providesfor sealed seams forming the coolant channel. Other assembly techniquesare contemplated herein. Each component of the assembly may be formed byany known techniques. It is desirable that the coolant channelseparating body be thermally conductive, and may be formed, for example,from aluminum. In certain embodiments, the coolant channel separatingbody is forged, although it may be cast, machined, or formed by anyother technique. In certain embodiments, the lower coolant channel coveris stamped. In certain embodiments, the main cover body is cast.Referencing FIG. 131, an example embodiment is depicted with the lowercoolant channel cover depicted in position, integrated with the maincover and the coolant channel separating body.

Referencing FIG. 117, the underside of the main cover is depicted withinsulated-gate bipolar transistors 11702 (IGBTs) installed. The IGBTs11702 are thermally coupled (e.g., using thermal adhesive) to thesurface of the upper cooling channel, and accordingly have a high heattransfer capacity to the coolant to support high power densityinstallations.

Referencing FIG. 118A, the dimensions and weight of an exampleintegrated inverter assembly 10900 are shown, where a width 11806 isabout 118 mm, and wherein a length 11804 is about 277 mm. ReferencingFIG. 118B, an example embodiment includes a depth 11802 of about 87 mm.An overall mass of an example inverter assembly 10900 is below about 5kg. The example of FIG. 118A is based upon various aspects of thepresent disclosure, and is believed to describe one example ofachievable dimensions having sufficient power capacity for an automotivepassenger car application.

Referencing FIG. 119, a perspective view depicting the gate driver PCB11902 and the DC link capacitor 11206 is shown. Referencing FIG. 120, aperspective view for an example embodiment depicts the AC bus bars11202, the motor temperature/position sensor 10906. The AC connectionutilizes two foam seals 12002 and replaceable captive nuts 13502 (alsoreference FIG. 35). Referencing FIG. 121, an underside view of the maincover is depicted. In the example of FIG. 121, a curable in-place gasket(CIPG) 12102 is dispensed and cured on the cover, and is reusable aftera service event if the gasket is not damaged during the service event.

Referencing FIG. 122, a close-up of one corner of the example main coveris depicted. In the example of FIG. 122, a ledge 12204 is provided thatprovides for controlled compression of the CIPG 12102, through selectionof the ledge height and CIPG dispensation (height difference 12202provides selectable compression), and accordingly provides for ease andreliability in proper installation and sealing of the main cover.Referencing FIG. 123, certain aspects of an example installation for theIGBTs is depicted, with thermal paste 12302 providing thermal couplingfor the IGBTs and the PCBs, and with formed-in-place-gaskets 12304providing reliable sealing for coolant flows between the coolingchannels. FIGS. 124-127 depict a number of views of an exampleembodiment of a main cover portion, with installed components, of anintegrated inverter assembly 12400 consistent with various aspects ofthe present disclosure. Referencing FIG. 125, a lower cooling channel11504 and side cutaway view of an IGBT 11702 provides an illustrativeheat transfer environment for the IGBTs 11702 of the integrated inverterassembly. Referencing FIG. 128, an example embodiment depicts the upper11506 and lower 11504 cooling channels, with an example location for atemperature sensor 12802 (a thermistor, in the example) which may beutilized, for example, to control active cooling, and/or to monitor thepower electronics.

An example IGBT consistent with certain embodiments of the presentdisclosure is a dual side cooling half-bridge power module, capable of750V, 800 A operation, and having an operating temperature capability of175° C. for continuous operation. Certain commercially available FS4IGBTs using a half-bridge configuration exhibit low losses at lightloads, and in certain embodiments are favorable to applications tendingto have a low duty cycle, such as passenger car applications.

Referencing FIG. 129, an example coupling mechanism for the main coverto the back cover is depicted. The example coupling mechanism includes athreaded area 12908 in the main cover to retain the coupling screw 12906when disengaged, and where the height 12902 of the unthreaded portion inthe motor casting (back cover) is greater than the threaded engagementportion 12904 of the screw 12906. Thus, the screw can be backed into thethreaded area 12908 in the main cover, and ensure that the threadsremain disengaged from the motor casting. Referencing FIG. 130, theexample coupling mechanism includes a reduced diameter portion 13004 fora portion of the coupling screw, providing for a convenient captivescrew mechanism. In the example of FIG. 130, the screw main threads13006 are disengaged from the motor casting, and a second threadedportion 13002 of the screw is engaged with the threaded area 12908 ofthe main cover. Referencing FIG. 131, a cutaway side view depicting

Referencing FIG. 132, a previously known DC Link Capacitor is depicted.The DC Link Capacitor includes a bus bar, common-mode choke, andcapacitors (Y-caps) as external elements to the DC Link Capacitor. Thebus bar is a laminated bus bar to provide isolation of the three ACphases, and the bus bar external to the DC Link Capacitor housing isrequired to be as long as the housing, with a full thickness along thelength of the housing.

Referencing FIG. 133, an example DC Link Capacitor 11206 is depicted,with the bus bar, common-mode choke, and Y-caps included in the housingof the DC Link Capacitor 11206. The bus bar, choke, and Y-caps arepotted within the DC Link Capacitor, providing for a compact design andenhanced mechanical integrity. In certain embodiments, the DC LinkCapacitor 11206 of the example in FIG. 133 can be utilized in anintegrated inverter assembly 10900 consistent with any other aspect ofthe present disclosure. The DC Link Capacitor 11206 further includes anIGBT interface 13302 providing power to each of the IGBTs, and a DCinterface 13304 providing an interface to DC power, such as to thebattery. Referencing FIG. 134, an example embodiment depicts the pottedDC Link Capacitor 11206 coupled to the three phases of the AC motorconnector through the IGBTs 11702. In the example of FIG. 134, theconnections are welded, providing for reduced assembly complexity andreduced contact resistance. In certain embodiments, the utilization ofan integrated inverter assembly 10900, with a fixed, small, footprint,and with limited external interfaces to the rest of the vehicle and/orelectrical drive system, enables one or both of the potted DC LinkCapacitor 11209 and the welded connections—for example by providing aconsistent geometric positioning allowing the parts to be assembledusing potting and welding without having to arrange or assemble thepositioning of the DC Link Capacitor, the bus bar, the common-modechoke, the Y-caps, and/or the spatial arrangement of the IGBTs and ACconnector blades. Referencing FIG. 135, another view of the embodimentdepicted in FIG. 126, where FIG. 135 is a cutaway view of the embodimentof FIG. 126, and can be used to reference the positioning of the DC LinkCapacitor assembly within the example integrated inverter assembly10900.

Referencing FIG. 136, a previously known quick connector consistent withthe SAEJ2044 quick connect coupling standard is depicted. The quickconnector of FIG. 136 includes a lock 13608 with a retaining spring, andtwo internal o-rings 13602 for sealing the fluid coupling. A spacer isprovided between the two internal o-rings. The quick connector of FIG.136 is configured to receive a fluid coupling such as an end piecehaving an end form (13702) such as that depicted in FIG. 26. The quickconnector of FIG. 136 includes ribbing (“fir tree”) 13606 on the outerdiameter of the tube connection, with an external o-ring 13604 on thetube-side for sealing.

Referencing FIG. 138, a first embodiment of a fluid connector of thepresent disclosure is depicted. The fluid connector of FIG. 138 does notinclude a locking element, but is configured to receive an end piecehaving a standard SAEJ2044 end form. The example fluid connectionincludes two internal o-rings 13804 and a spacer 13806 therebetween. Theconnector further includes a shaped receiving portion 13802 and does notinclude a lock. the connector further includes an external o-ring 13808.In certain embodiments, fluid connections within the integrated inverterassembly 10900 have a tight spacing and poor access (or no access) toportions of a quick connector to manipulate the lock and thereby operatethe quick connector. Additionally, in certain embodiments, theintegrated inverter assembly 10900 provides for a fixed geometry offluid coupling positions, which are at least partially internal to thehousing of the integrated inverter assembly 10900, and thereby providefor a secure fluid connection without the lock. Accordingly, it can beseen that a quick connector embodiment such as that depicted in FIG.138, improves and/or enables certain aspects of the integrated inverterassembly 10900.

Referencing FIG. 139, a second embodiment of a fluid connector of thepresent disclosure is depicted. The fluid connector of FIG. 139 does notinclude a locking element, but is configured to receive an end piecehaving a standard SAEJ2044 end form. Additionally, it can be seen thatthe fluid connector of the example in FIG. 139 omits the rightextension, utilizing the housing of the fluid connector to form theribbing 13902 and support the seal. The fluid connector of the examplein FIG. 139 further includes the o-ring 13808 on the outer body. Againreferencing FIG. 115, it can be seen that the fluid connector for thecoolant outlet depicted in FIG. 115 is consistent with the quickconnector embodiment of FIG. 139. It can further be seen that the quickconnector depicted in FIG. 139 provides for a greatly reduced verticalfootprint of the fluid connection, allowing for a more compact footprintof the integrated inverter assembly. The embodiment of FIG. 115additionally depicts a hose coupled to the quick connector that providesfor compliance in the horizontal and vertical planes (using baffled hose11502), further enhancing the ease of installation of the coolantconnection. It can further be seen that the coolant channel separatingbody 11604 (e.g. reference FIG. 116) includes an integrated hose nippleconfigured to couple with the quick connector, thereby further reducingthe footprint and the assembly complexity of the integrated inverterassembly 10900. A given embodiment of the integrated inverter assembly10900 may utilize one or both of the quick connector embodiments ofFIGS. 138 and 139, or neither of these.

An example breaker/relay may include a fixed contact electricallycoupled to a power bus for a mobile application, a moveable contactselectively electrically coupled to the fixed contact, an armatureoperationally coupled to the moveable contact, such that the armature ina first position prevents electrical coupling between the moveablecontact and the fixed contact, and the armature in a second positionallows electrical coupling between the moveable contact and the fixedcontact. The example breaker/relay further includes a first biasingmember biasing the armature into one of the first position or the secondposition, a standard on/off circuit having at least two states, whereinthe standard on/off circuit in a first state provides an actuatingsignal and in a second state prevents the actuating signal. ReferencingFIG. 40, an example current response circuit 14002 is depicted that maybe utilized with any system or to perform any operations describedthroughout the present disclosure. The example current response circuit14002, determines a current in the power bus 14004, and further blocksan actuating signal 14006 of the standard on/off circuit in response tothe current in the power bus 14006 indicating a high current value14003. The actuating signal may be provided as an armature positioncommand 14008, where an armature is responsive to the actuating signalto electrically couple the moveable contact to the fixed contact. Inembodiments, the mobile application may include at least two electricalcurrent operating regions. The current response circuit 14002 may befurther structured to adjust the high current value 14003 in response toan active one of the at least two electrical current operating regions.

Referencing FIG. 141, an example procedure 14100 for opening a contactis schematically depicted. Operations of the procedure 14100 may beperformed by any controllers, circuits, and/or hardware arrangements asdescribed throughout the present disclosure, and further may beperformed in relation to any of the systems or hardware arrangementsdescribed throughout the present disclosure. In an aspect, the procedure14100 includes an operation 14102 to select contact force for abreaker/relay such that the opening the contacts occurs at a selectedcurrent flow value of the electrical current flow through the contacts.The procedure 14100 further includes an operation 14104 to apply acontact force to the moveable contact of the breaker/relay, and anoperation 14106 to determine a current value through the contacts. Theprocedure 14100 further includes an operation 14108 to determine whetherthe current value exceeds a threshold value, and an operation 14110 tocommand an armature or actuator to open the contacts in response to thecurrent value exceeding the threshold. The example procedure 14100further includes an operation 14112 to open the contacts in response toa repulsive force on the contacts—for example as a physical response ofthe moveable contact at the selected current flow value. In certainembodiments, the operation 14110 may be commenced before the operation14112. In certain embodiments, the operation 14110 is performed suchthat the moveable contact does not return to the closed position afterthe operation 14112 to open the contacts (e.g., relieving the returnforce of the moveable contact that may otherwise drive the contact backto a closed position after the physical opening operation 14112).

Referencing FIG. 142, an example procedure 14200 for opening a contactis schematically depicted. Operations of the procedure 14200 may beperformed by any controllers, circuits, and/or hardware arrangements asdescribed throughout the present disclosure, and further may beperformed in relation to any of the systems or hardware arrangementsdescribed throughout the present disclosure. The example procedure 14200includes an operation 14202 to determine a first threshold (for currentin an electric load circuit) in response to a first physical currentopening value (e.g., based on the opening characteristics for acontactor), an operation 14204 to determine a second threshold inresponse to a second physical current opening value, an operation 14206to determine a first current value in a first electric load circuit, andan operation 14208 to determine a second current value in a secondelectric load circuit. The procedure 14200 further includes an operation14210 to determine whether the first current value exceeds the firstthreshold, and/or whether the second current value exceeds the secondthreshold. The example procedure 14200 includes an operation 14214 tocommand an armature (or actuator) for the first contactor to open if thefirst threshold is exceeded, and an operation 14212 to diffuse an arcfrom the first contact (e.g., using splitter plates and/or a magnet).The example procedure 14200 includes an operation 14216 to command anarmature for the second contactor to open if the second threshold isexceeded, and an operation 14218 to diffuse an arc of the secondcontactor. In certain embodiments, determining the first or secondthreshold includes providing components configured to provide a selectedvalue for the first or second threshold (e.g., selected contact areas,contact force values, and/or bus bar configurations). In certainembodiments, procedure 14200 is utilized in relation to a system havingmore than one contactor, where each contactor is separatelycontrollable.

In an aspect, a system may include a housing; a breaker/relay devicepositioned in the housing, wherein the breaker/relay device may beconfigured to interrupt a motive power circuit for an electrical vehiclesystem, where the housing may be disposed on the electrical vehiclesystem; wherein the breaker/relay device may include a physical openingresponse portion responsive to a first current value in the motive powercircuit, and a controlled opening response portion responsive to asecond current value in the motive power circuit; and a prechargecircuit electrically coupled in parallel to the breaker/relay device. Inembodiments, the precharge circuit may be positioned within the housing.The first current value may be greater than the second current value.The physical opening response portion may include a first biasing memberbiasing an armature of the breaker/relay device into an open positionfor a contactor of the motive power circuit, and a selected differencebetween a first force of the armature closing the contactor and a secondforce of the first biasing member opening the contactor. The controlledopening response portion may include a current sensor providing acurrent value through the motive power circuit, and a current responsecircuit 14304 (reference FIG. 143) structured to command an armature toopen a contactor in response to the current value 14314 exceeding thesecond current value 14316. The breaker/relay device may include adual-pole breaker/relay device. The breaker/relay device may include asingle-pole breaker/relay device. The breaker/relay device may bepositioned on one of a high side circuit or a low side circuit of themotive power circuit. The system may further include a pyro-switchdevice positioned on the other of the high side circuit or the low sidecircuit.

Referencing FIG. 43, an example system includes a physical openingresponse adjustment circuit 14302 that determines a first current valueadjustment 14312, and adjusts the physical opening response portion inresponse to the first current value adjustment 14312. The physicalopening response adjustment circuit 14302 may be further structured toadjust the physical opening response portion by providing an adjustmentimplementation command 14310, which may include adjusting a compressionof the first biasing member; adjusting the first force (e.g., the forceapplied by the armature); and/or adjusting the second force (e.g., theforce of the compression spring). The physical opening responseadjustment circuit 14302 may be further structured to adjust thephysical opening response portion in response to an operating condition14308 of the electrical vehicle system. Example and non-limitingoperating conditions 14302 include a time-current profile of the motivepower circuit; a time-current trajectory of the motive power circuit; atime-current area value of the motive power circuit; a rate of change ofa current value through the motive power circuit; and/or a differencebetween a current value through the motive power circuit and the secondcurrent value.

Referencing FIG. 144, an example procedure 14400 for opening a contactis schematically depicted. Operations of the procedure 14400 may beperformed by any controllers, circuits, and/or hardware arrangements asdescribed throughout the present disclosure, and further may beperformed in relation to any of the systems or hardware arrangementsdescribed throughout the present disclosure. The example procedure 14400includes an operation 14402 to determine a physical opening responseadjustment for a contactor—for example where operating conditions of anelectric mobile application indicate that the current flow through aload circuit should be permitted to be increased, or reduced, includingduring high performance operation, charging operation, and/or emergencyoperation. The example procedure 14400 further includes an operation14404 to adjust a physical opening response value for a contactor, andan operation 14406 to determine a current in a load circuit (e.g., amotive power circuit) of the electric mobile application. The exampleprocedure 14400 further includes an operation 14408 to determine whethera current value in the load circuit exceeds a controlled open thresholdvalue, and an operation 14410 to command an armature (or actuator) ofthe contactor to an open position in response to the current exceedingthe controlled open threshold value. In certain embodiments, thecontrolled open threshold value is distinct from, and may be lower than,the physical open threshold value. The example procedure 14400 furtherincludes an operation 14412 to determine whether the current valueexceeds a physical open threshold, and an operation 14414 to open thecontacts in response to a repulsive force in the contactor in responseto the determination 14412 indicating a YES value. In certainembodiments, operations described throughout the present disclosure todetermine whether a physical open current value is exceeded includeoperation to configure a contactor (e.g., within a breaker/relay) toopen at a selected current value, to expose the contactor to a loadcurrent, where the contact responds to the load current according to theconfiguration made in response to the selected current value. The orderof determinations 14408, 14412 may be reversed, and/or one or moredeterminations 14408, 14412 may be omitted. Operations 14402 todetermine a physical opening response adjustment may be performed duringrun-time operations or design-time operations of a system, and similarlyoperations 14404 to adjust the physical opening response may beperformed during run-time operations or design-time operations.

Referencing FIG. 145, an example procedure 14500 for opening a contactis schematically depicted. Operations of the procedure 14500 may beperformed by any controllers, circuits, and/or hardware arrangements asdescribed throughout the present disclosure, and further may beperformed in relation to any of the systems or hardware arrangementsdescribed throughout the present disclosure. The example procedure 14500includes an operation 14502 to configure a physical response openingportion of a breaker/relay of a mobile power circuit to provide for anopening of the contactor of the breaker/relay based on a physicalopening response threshold current. Example and non-limiting operations14502 include an operation 14502A to select a mass (e.g., of the movingportion of a moveable contact), a Lorentz force area (e.g., contactarea, bus bar area in the region of the contact, etc.), and/or to selecta contact force (e.g., adjust a strength or number of engaged biasingmembers, and/or to change an amount of compression on a biasing member,and/or to change a movement position of an actuator for the moveablecontact). In certain embodiments, configuring the physical openingresponse portion may include selecting a bus bar configuration, whereinthe bus bar couples two moveable contacts, and wherein the bus barconfiguration may include at least one of a bus bar area in proximity toa current providing portion of the mobile power circuit or a positioningof a portion of the bus bar in proximity to the current providingportion of the mobile power circuit. The example procedure 14500 furtherincludes an operation 14504 to operate a moveable contact of thebreaker/relay between open and/or closed positions—for example moving tothe closed position to allow for power flow through the contactor, andto the open position to prevent power flow through the contactor. Theexample procedure 14500 further includes an operation 14506 to determinea current value in the mobile power circuit, and an operation 14508 tocommand the moveable contact to an open position based on a separatecurrent threshold from the physical opening current threshold. Incertain embodiments, the separate current threshold utilized inoperation 14508 is a lower current threshold than the configuredphysical opening response threshold current.

In an aspect, referencing FIG. 146, a system may include a vehiclehaving a motive electrical power circuit 14600 (or power path) between apower source 14601 and a load 14608, and a power distribution unithaving a current protection circuit disposed in a motive electricalpower circuit 14600. an example current protection circuit includes abreaker/relay 14602, a breaker/relay including a fixed contactelectrically coupled to a motive power circuit for a mobile application,a moveable contact selectively electrically coupled to the fixedcontact, and where the moveable contact in a first position allows powerto flow through the motive power circuit, and the moveable contact in asecond position does not allow power to flow through the motive powercircuit, and a physical opening response portion responsive to a currentvalue in the motive power circuit, wherein the physical opening responseportion may be configured to move the moveable contact to the secondposition in response to the current value exceeding a threshold currentvalue. The example current protection circuit 14600 includes a contactor14604 in parallel with the breaker/relay 14602; a pair of breaker/relays14602, 14702 in parallel (e.g., reference FIG. 147) and/or a dual polebreaker relay 14602 providing two parallel electrical paths; and/or abreaker/relay 14602 in parallel with a contactor 14604 and a fuse 14802(e.g. reference FIG. 148). In certain embodiments, the currentprotection circuit 14600 includes a contactor in series with abreaker/relay.

In an aspect, referencing FIG. 146, a system may include a vehiclehaving a motive electrical power circuit 14600 (or power path) between apower source 14601 and a load 14608, and a power distribution unithaving a current protection circuit disposed in a motive electricalpower circuit 14600. an example current protection circuit includes abreaker/relay 14602, a breaker/relay including a fixed contactelectrically coupled to a motive power circuit for a mobile application,a moveable contact selectively electrically coupled to the fixedcontact, and where the moveable contact in a first position allows powerto flow through the motive power circuit, and the moveable contact in asecond position does not allow power to flow through the motive powercircuit, and a physical opening response portion responsive to a currentvalue in the motive power circuit, wherein the physical opening responseportion may be configured to move the moveable contact to the secondposition in response to the current value exceeding a threshold currentvalue. The example current protection circuit 14600 includes a contactor14604 in parallel with the breaker/relay 14602; a pair of breaker/relays14602, 14702 in parallel (e.g., reference FIG. 147) and/or a dual polebreaker relay 14602 providing two parallel electrical paths; and/or abreaker/relay 14602 in parallel with a contactor 14604 and a fuse 14802(e.g. reference FIG. 148). In certain embodiments, the currentprotection circuit 14600 includes a contactor 14604 in series with abreaker/relay 14902 (e.g., reference FIG. 149). The utilization of abreaker/relay in series with a contactor allows the breaker/relay toopen the circuit, thereby allowing the contactor to open when thecircuit is not powered. The utilization of a breaker/relay in parallelwith a contactor allows the contactor to open when the circuit ispowered, and to allow the breaker/relay to open the circuit.

The power distribution unit further may include a plurality ofbreaker/relay devices disposed therein, and wherein the current sourcecircuit 15002 may be further electrically coupled to the plurality ofbreaker/relay devices, and to sequentially inject a current across eachfixed contact of the plurality of breaker/relay devices; and wherein thevoltage determination circuit 15006 may be further electrically coupledto each of the plurality of breaker/relay devices, and furtherstructured to determine at least one of an injected voltage amount and acontactor impedance value for each of the plurality of breaker/relaydevices (e.g., voltage drop determinations 15008). The current sourcecircuit 15002 may be further structured to sequentially inject thecurrent across each of the plurality of breaker/relay devices in aselected order of the breaker/relay devices. The current source circuit15002 may be further structured to adjust the selected order in responseto one or more operating conditions 15016 or stored properties 15018such as: a rate of change of a temperature of each of the fixed contactsof the breaker/relay devices; an importance value of each of thebreaker/relay devices; a criticality of each of the breaker/relaydevices; a power throughput of each of the breaker/relay devices; and/ora fault condition or a contactor health condition of each of thebreaker/relay devices. The current source circuit 15002 may be furtherstructured to adjust the selected order in response to an operatingcondition 15016 such as a planned duty cycle and/or an observed dutycycle of the vehicle. The current source circuit 15002 may be furtherstructured to sweep the injected current through a range of injectionfrequencies. The current source circuit 15002 may be further structuredto inject the current across the fixed contact at a plurality ofinjection frequencies. The current source circuit 15002 may be furtherstructured to inject the current across the fixed contact at a pluralityof injection voltage amplitudes. The current source circuit 15002 may befurther structured to inject the current across the fixed contact at aninjection voltage amplitude determined in response to an operatingcondition 15106 such as a power throughput of the breaker/relay devices.The current source circuit 15002 may be further structured to inject thecurrent across the fixed contact at an injection voltage amplitudedetermined in response to a duty cycle of the vehicle.

In an aspect, a system may include a vehicle having a motive electricalpower path; a power distribution unit including a current protectioncircuit disposed in the motive electrical power path, the currentprotection circuit including breaker/relay, the breaker/relay includinga fixed contact electrically coupled to a motive power circuit for amobile application; a moveable contact selectively electrically coupledto the fixed contact, wherein the moveable contact in a first positionallows power to flow through the motive power circuit, and the moveablecontact in a second position does not allow power to flow through themotive power circuit; and a physical opening response portion responsiveto a current value in the motive power circuit, wherein the physicalopening response portion may be configured to move the moveable contactto the second position in response to the current value exceeding athreshold current value; a current source circuit 15002 electricallycoupled to the breaker/relay and structured to inject a current(injection command 15004) across the fixed contact; and a voltagedetermination circuit 15006 electrically coupled to the breaker/relayand structured to determine an injected voltage amount and a contactorimpedance value (voltage drop determination 15008), wherein the voltagedetermination circuit 15006 may be structured to perform a frequencyanalysis operation to determine the injected voltage amount. Inembodiments, the voltage determination circuit 15006 may be furtherstructured to determine the injected voltage amount by determining anamplitude of a voltage across the fixed contact at a frequency ofinterest. The frequency of interest may be determined in response to afrequency of the injected voltage. The current source circuit 15002 maybe further structured to sweep the injected current through a range ofinjection frequencies. The current source circuit 15002 may be furtherstructured to inject the current across the fixed contact at a pluralityof injection frequencies. The current source circuit 15002 may befurther structured to inject the current across the fixed contact at aplurality of injection voltage amplitudes. The current source circuit15002 may be further structured to inject the current across the fixedcontact at an injection voltage amplitude determined in response to apower throughput of the breaker/relay. The current source circuit 15002may be further structured to inject the current across the fixed contactat an injection voltage amplitude determined in response to a duty cycleof the vehicle.

Referencing FIG. 152, an example procedure 15200 for configuring anX-in-1 power converter is schematically depicted. Operations of theprocedure 15200 may be performed by any controllers, circuits, and/orhardware arrangements as described throughout the present disclosure,and further may be performed in relation to any of the systems orhardware arrangements described throughout the present disclosure. Incertain embodiments, the procedure 152 may be utilized with any systemhaving configurable power electronics, a multi-port power converter, an“X” port power converter, and/or an X-in-1 port power converter. Theutilization of the terms multi-port, X port, and/or X-in-1 port indicatethat a power converter includes one or more ports that can servedistinct power loads and/or power sources with one or more varyingelectrical characteristics. A configurable power converter may have oneor more fixed ports, one or more configurable ports, or combinations ofthese.

The example procedure 15200 includes an operation to interpret a portelectrical interface description (or specification), where the portelectrical interface description includes a description of (or aspecification of) electrical characteristics for at least one of aplurality of ports of a power converter for an electric mobileapplication. The example procedure 15200 further includes an operation15204 to provide solid switch states in response to the port electricalinterface description, thereby configuring at least one of an ACinverter or a DC/DC converter to provide power to the at least one ofthe plurality of ports according to the port electrical interfacedescription. In certain embodiments, operation 15204 provides solidswitch states to configure at least one of a rectifier or a DC/DCconverter to interface with a power source (e.g., a battery, capacitor,regenerative state of a load, or the like), and/or to configure a portto accept power under certain operating conditions, and to provide powerunder other operating conditions. Without limitation, configurableelectrical characteristics include voltage levels, frequency values,phase values (including a number and arrangement of phases), and/ortolerances to one or more of these.

The example procedure 15200 further includes an operation 15206 tointerpret a source/load drive characteristic (e.g., frequency, phase, orother characteristics of an electric motor, motor/generator, or otherdevice), and an operation 15208 to provide a component driverconfiguration (e.g., gate drivers for an insulated-gate bipolartransistor) in response to the source/load drive characteristic. Incertain embodiments, one or more aspects of the procedure 15200 may beperformed at various periods in the life cycle of the power converterand/or an electric mobile application having the power converter, suchas: design time (e.g., specifying setting for a power converter), atinstallation time (e.g., configuring settings for the power converteraccording to a specification and/or needs of a particular installation),as a service operation (e.g., adjusting the configuration as a part of atest, to correct a failed or faulted component, and/or as a diagnosticoperation), as a remanufacture operation (e.g., testing and/orconfirming operations of the power converter, configuring the powerconverter to a standard state or a planned state for installation,etc.), as an upfit operation (e.g., providing an electric mobileapplication with an uprated capability such as a greater power rating,changing of a voltage and/or current rating through a port, addition ofpower inputs or outputs, changing one of the power inputs or outputs,and/or addition of phases or other capabilities to interface with loadsor power sources), at a manufacture time (e.g., configuring settings forthe power converter according to a specification and/or needs of aparticular installation, testing and/or confirming operations of thepower converter, configuring the power converter to a standard state ora planned state for installation, etc.), and/or as an application changeoperation (e.g., a conversion of an electric mobile platform to adifferent service operation, duty cycle, and/or the addition or removalof one or more loads or power sources).

Referencing FIG. 153, an example procedure 15300 for integrating a powerconverter into an electric mobile application is depicted. Operations ofthe procedure 15300 may be performed by any controllers, circuits,and/or hardware arrangements as described throughout the presentdisclosure, and further may be performed in relation to any of thesystems or hardware arrangements described throughout the presentdisclosure. The example procedure 15300 includes an operation 15302 toprovide a power converter having a number of ports for interfacing toelectrical loads and/or sources, an operation 15304 to determine anelectrical interface description for an electric mobile application, andan operation 15306 to provide solid state switch states in response tothe electrical interface description. The example procedure 15300further includes an operation 15308 to install the power converter inthe electric mobile application, and an operation 15310 to couplecoolant ports of the power converter to a cooling system of the electricmobile application. It can be seen that procedure 15300 provides forrapid and low cost integration with a number of electric mobileapplications, including both the design and engineering for theintegration, as well as simplified installation operations. The exampleprocedure 15300 provides for the capability to meet multipleapplications with a single power converter device, and/or with a smallnumber of power converter devices having a similar (or identical)footprint and interface locations. The procedure 15300 further includesthe capability to provide for a simple cooling interface to powerelectronics for the electric mobile application without having a numberof cooling connections and cooling fluid routing challenges to providecooling for multiple power electronics components distributed around theelectric mobile application.

Referencing FIG. 154, an example procedure 15400 for adjusting motoroperations in response to a motor temperature is schematically depicted.Operations of the procedure 15400 may be performed by any controllers,circuits, and/or hardware arrangements as described throughout thepresent disclosure, and further may be performed in relation to any ofthe systems or hardware arrangements described throughout the presentdisclosure. The example procedure 15400 includes an operation 15402 tooperate a motor for an electric mobile application, and an operation15404 to determine a motor temperature value (e.g., a modeled motortemperature, inferred motor temperature, and/or a motor temperaturedetermined from a virtual sensor). Example operations 15404 to determinethe motor temperature include, without limitation, determining andconsidering parameters such as: a power throughput of the motor,determining a voltage and/or current input value to the motor, adjustingthe motor temperature value based on ambient temperature values,determining a motor efficiency value at the current operating conditions(e.g., to separate useful work energy from potentially heat generatingenergy throughput), and/or utilizing the rates of change of these.

The example procedure 15400 further includes an operation 15406 todetermine a sensed temperature value for the motor. Example operations15406 to determine the sensed motor temperature include, withoutlimitation: determining a temperature from a sensor positioned toprovide a temperature representative of the motor; determining atemperature from a sensor positioned to provide a temperature associatedwith the motor (e.g., having a known offset from the motor temperature,and/or from which the motor temperature can be derived); and/ordetermining a temperature from a sensor positioned to provide atemperature from which a temperature of interest of the motor isdetermined. For example, an operation 15406 includes applying a hot spotadjustment correction to the sensed motor temperature (e.g., where atemperature of interest is of a hottest location in the motor, which maynot be reflected in a bulk temperature reading by a sensor). In certainembodiments, a hot spot adjustment correction may be calibrated as anoffset from a detected temperature (which may be scheduled, e.g., as afunction of the detected temperature), and/or from a calibratedrelationship between the detected temperature and the hot spottemperature. In certain embodiments, the hot spot adjustment correctionmay further include dynamic information related to the sensedtemperature, such as rates of change of the sensed temperature or powerthrough the motor, and/or integration based parameters of the sensedtemperature or power through the motor (e.g., accumulators, time valuesrelative to threshold values, etc.).

The example procedure 15400 further includes an operation 15408 toadjust an operating parameter for the motor in response to thetemperature values (e.g., the motor temperature value and the sensedmotor temperature value). Example and non-limiting operations 15408include: adjusting a rating of the motor (e.g., de-rating the motor,allowing greater power output of the motor, adjusting a voltageparameter of the motor to reduce heat production, etc.); adjusting arating of a load of the electric mobile application (e.g., limiting therequested power and/or torque based on a temperature-induced limitationof the motor); adjusting an active cooling amount for the motor (e.g.,engaging active cooling and/or changing a flow rate of active cooling tothe motor); and/or adjusting an operating space of the motor based on anefficiency map of the motor (e.g., shifting the motor to a moreefficient operating point to reduce heat generation, allowing the motorto operate at a less efficient operating point—for example to allow fora system-level optimization or efficiency routine, etc.).

Referencing FIG. 155, an example procedure 15500 to determinereliability values for the sensed motor temperature value and/or themodeled/estimated motor temperature value is schematically depicted. Theprocedure 15500 includes an operation 15502 to determine a firstreliability value for the motor temperature value (e.g., the modeled,estimated, or virtual motor temperature value) in response to a firstoperating condition for the motor. For example, a model or estimator mayhave a valid range, a known relationship to uncertainty based onoperating condition regions, and/or depend upon other sensors ordetermined values having a fault or failure condition. The exampleprocedure 15500 further includes an operation 15504 to determine asecond reliability for the sensed motor temperature value. For example,the sensed motor temperature value may have a fault condition or afailure condition for the associated sensor, the sensor may have a timeconstant that is slower than currently observed temperature changes,and/or the sensor may be saturated, have a low resolution, and/or have areduced accuracy in certain temperature or other operating conditions.Example and non-limiting operating conditions to determine the firstreliability value include: a power throughput of the motor; a rate ofchange of power throughput of the motor; a defined range value for amodel used to determine the motor temperature value; and/or a rate ofchange of one of the motor temperature value or the effective motortemperature value. Example and non-limiting operating conditions todetermine the second reliability value include: a power throughput ofthe motor; a rate of change of power throughput of the motor; a definedrange value for a temperature sensor providing the sensed motortemperature value; a defined temperature-accuracy relationship for atemperature sensor providing the sensed motor temperature value; aresponse time for a temperature sensor providing the sensed motortemperature value; and a fault condition for a temperature sensorproviding the sensed motor temperature value.

The example procedure 15500 further includes an operation 15506 todetermine an effective motor temperature value in response to the motortemperature value and the sensed motor temperature value, and in certainembodiments the operation 15506 further determined the effective motortemperature in response to the first reliability value and the secondreliability value. An example operation 15506 includes choosing one orthe other of the motor temperature value or the sensed motor temperaturevalue as the effective motor temperature value based on the firstreliability value and the second reliability value; and/or utilizing oneor the other of the motor temperature value or the sensed motortemperature value as a target for the effective motor temperature valuebased on the first reliability value and the second reliability value(e.g., where the effective motor temperature value is a filtered valuemoving toward the target). In certain embodiments, the effective motortemperature value, or the target for the effective motor temperaturevalue, use a mixing of the motor temperature value and/or the sensedmotor temperature value (e.g., a weighted average as a function of thereliability values). In certain embodiments, for example where one orthe other of the motor temperature value or the sensed motor temperaturevalue are utilized to drive the effective motor temperature value, theoperation 15506 may further include hysteresis or other processing(e.g., filtering, averaging, rate-limiting, etc.), for example to avoiddithering of the effective motor temperature value. In certainembodiments, procedure 15500 is utilized in combination with procedure15400—for example utilizing the effective motor temperature value as aninput to operation 15408, and adjusting an operating parameter of themotor in response to the effective motor temperature value.

The term a motor temperature value, or a temperature of the motor,should be understood broadly. A motor temperature value may be anytemperature value of interest that is related to the motor—for example ahottest position within the motor, a component of the motor that is mostprone to failure in response to temperature excursions, a component ofthe motor that is most prone to affect some other component of thesystem in response to temperature excursions, and/or a temperaturerelated to the motor that correlates with an effective efficient powerconversion of the motor. Example and non-limiting motor temperaturevalues include, without limitation: a winding temperature of the motor,a bus bar temperature for a bus bar providing power to the motor, aconnector temperature related to the motor, and/or a hot spottemperature of the motor.

Referencing FIG. 156, in an aspect, an apparatus 15600 may include amotor control circuit 15602 structured to operate a motor for anelectric mobile application; an operating conditions circuit 15604structured to interpret a sensed motor temperature value 15608 for themotor, and further structured to interpret at least motor temperaturerelevant operating condition 15620 such as: a power throughput of themotor; a voltage input value to the motor; a current input value to themotor; an ambient temperature value; and/or an active cooling amount forthe motor. An example apparatus 15600 includes a motor temperaturedetermination circuit 15606 structured to determine a motor temperaturevalue 15614 in response to the motor temperature relevant operatingcondition(s) 15620. An example motor temperature determination circuit15606 further determines a motor effective temperature value 15612 inresponse to the motor temperature value 15614 and the sensed motortemperature value 15608; where the motor control circuit 15602 may befurther structured to adjust at least one operating parameter for themotor (e.g., as an updated motor command 15610) in response to the motoreffective temperature value 15614. In embodiments, the motor temperaturedetermination circuit 15606 may be further structured to determine afirst reliability value for the motor temperature value in response to afirst operating condition for the motor and determine a secondreliability value for the sensed motor temperature value in response toa second operating condition for the motor (reliability values 15616),and determine the motor effective temperature value 15612 further inresponse to the reliability values 15616.

The motor temperature determination circuit 15606 may be furtherstructured to use the sensed motor temperature value 15608 as the motoreffective temperature value in response to the second reliability valueexceeding a threshold value. The motor temperature determination circuit15606 may be further structured to apply a temperature adjustment 15618such as an offset component adjustment or a hot spot adjustment to thesensed motor temperature value 15608, and determine the motor effectivetemperature value 15612 further in response to the adjusted sensed motortemperature value. The motor temperature determination circuit 15606 maybe further structured to determine the first reliability value inresponse to at least one operating condition 15620 such as: the powerthroughput of the motor; a rate of change of power throughput of themotor; a defined range value for a model used to determine the motortemperature value; and a rate of change of one of the motor temperaturevalue or the effective motor temperature value. The motor temperaturedetermination circuit 15606 may be further structured to determine thesecond reliability value in response to at least one operating condition15620 such as: the power throughput of the motor; a rate of change ofpower throughput of the motor; a defined range value for a temperaturesensor providing the sensed motor temperature value; a response time fora temperature sensor providing the sensed motor temperature value; and afault condition for a temperature sensor providing the sensed motortemperature value. The motor control circuit 15606 may be furtherstructured to adjust at least one operating parameter (e.g., an adjustedmotor command 15610) for the motor such as: a rating of the motor; arating of a load of the electric mobile application; the active coolingamount for the motor; and an operating space of the motor based on anefficiency map of the motor.

In an aspect, a system may include an electric mobile application havinga motor and an inverter, wherein the inverter may include a plurality ofdriving elements for the motor. Referencing FIG. 157, the example systemfurther includes a controller 15700 having a motor control circuit 15702structured to provide driver commands (driving element commands 15704),and where the plurality of driving elements may be responsive to thedriver commands 15704. The controller 15700 further includes anoperating conditions circuit 15706 structured to interpret a motorperformance request value 15708 such as a power, speed, and/or torquerequest for the motor. The controller 15700 further includes a driverefficiency circuit 15710 that interprets a driver activation value 15712for each of the plurality of driving elements of the inverter inresponse to the motor performance request value 15708, and where themotor control circuit 15702 may be further structured to provide thedriver commands 15704 to de-activate at least one of the drivingelements for the motor in response to the driver activation value 15712for each of the plurality of driving elements of the inverter. Inembodiments, the motor may include a three-phase AC motor, wherein theplurality of driving elements include six driving elements, and whereinthe driver efficiency circuit 15710 provides the driver activation value15712 to de-activate three of the six driving elements in response tothe motor performance request value 15708 being below a threshold value.

Referencing FIG. 158, an example procedure 15800 for selectivelyde-activating portions of a power inverter for an electric mobileapplication is depicted. Operations of the procedure 15800 may beperformed by any controllers, circuits, and/or hardware arrangements asdescribed throughout the present disclosure, and further may beperformed in relation to any of the systems or hardware arrangementsdescribed throughout the present disclosure. The example procedure 15800includes an operation 15802 to provide driver commands to a plurality ofdriving elements of an inverter electrically coupled to a motor for anelectric mobile application, and an operation 15804 to interpret a motorperformance request value for the electric mobile application. Exampleand non-limiting motor performance request values include, withoutlimitation, a power, a speed, and/or or a torque request for a motorpowered by the power inverter. The example procedure 15800 furtherincludes an operation 15806 to interpret a driver activation value foreach of the plurality of driving elements in response to the motorperformance request value. For example, if the motor performance requestvalue includes a power request requiring all of the driving elements(e.g., IGBTs on an inverter) to be active to accommodate the powerrequest, then operation 15806 may determine that the driver activationvalue for each driving element is “TRUE”. In another example, if themotor performance request value includes a power request where only aportion of the driving elements are required to meet the power request,the operation 15806 may include determining whether some of the drivingelements may be deactivated. In a further example, the operation 15806may include determining an efficiency of the driving elements in a firstcondition (e.g., all driving elements active), and the efficiency of thedriving elements in a second condition (e.g., some driving elementsinactive), and determining the driver activation values that meet thedesired goals (e.g., power conversion efficiency, temperature targetsfor driving elements, planned life cycle of the driving elements, noiseor electrical characteristic requirements of the motor or load, etc.).The example procedure 15800 further includes an operation 15806 toprovide driver commands to the driving elements in response to thedriver activation values, including deactivating one or more drivingelements in response to the driver activation value(s). An exampleprocedure 15800 includes the operation 15806 to deactivate three out ofsix total driving elements (e.g., retaining capability to support threebalanced phases to drive a motor). A further example procedure 15800includes the operation 15806 to deactivate a first three out of sixtotal driving elements during a first de-activation operation, andde-activating a second three out of the six total driving elementsduring a second de-activation (e.g., to balance the life cycles ofdriving elements, to balance heat generation within the inverter overtime, to utilize banks of driving elements having distinct capabilitiessuch as power ratings, etc.).

Referencing FIG. 159, an example system 15900 may include an electricmobile application having a plurality of electric motors 15904, 15908,15912, 15916, each one of the plurality of electric motors operationallycoupled to a corresponding one of a plurality of electric loads 15906,15910, 15914, 15918. The example system 15900 includes four motorscoupled to four loads, although a system may include any number ofmotors coupled to any number of loads, and the motors and loads may havemore than one motor for a given load, and/or more than one load for agiven motor. The system includes a controller 15902, where thecontroller 15902 includes (Reference FIG. 160) an application loadcircuit 16002 structured to interpret an application performance requestvalue 16010; a performance servicing circuit 16004 structured todetermine a plurality of motor commands 16020 in response to a motorcapability description (motor performance capability 16016), and theapplication performance request value 16010. The controller 15902further includes a motor control circuit 16006 structured to provide theplurality of motor commands 16014 to corresponding motors 15904, 15908,15912, 15916 of the plurality of electric motors; and wherein theplurality of electric motors 15904, 15908, 15912, 15916 may beresponsive to the plurality of motor commands 16014. The determinedmotor commands 16020 may differ from the communicated motor commands16014, for example to account for system dynamics, rate change limits,and/or other constraints not related to meeting performance requests ofthe system.

In embodiments, the performance servicing circuit 16004 may be furtherstructured to determine the plurality of motor commands 16020 inresponse to one of a fault condition or a failure condition 16012 for atleast one of the plurality of electric motors, and/or for a componentrelated to one of the plurality of electric motors (e.g., a localinverter, local controller, sensor, and/or the load). The performanceservicing circuit 16004 may be further structured to determine theplurality of motor commands 16020 to meet the application performancerequest value 16010 by at least partially redistributing loadrequirements from one of the plurality of electric motors having thefault condition or the failure condition 16012, to at least one of theplurality of electric motors having available performance capacity (butwhich may have a separate fault condition or failure condition 16012).The performance servicing circuit 16004 may be further structured toderate one of the plurality of electric motors in response to the one ofthe fault condition or the failure condition 16012. The system mayfurther include a first data store 16024 associated with a first one ofthe plurality of electric motors, a second data store 16026 associatedwith a second one of the plurality of electric motors, and wherein thecontroller 15902 further may include a data management circuit 16008structured to command at least partial data redundancy (e.g., redundantdata value(s) 16022) between the first data store 16024 and the seconddata store 16026, and/or between one of the data stores 16024, 16026,and another data store in the system (not shown) and/or to an externaldata store. The at least partial data redundancy may include at leastone data value selected from the data values consisting of: a faultvalue, a system state, and a learning component value. The datamanagement circuit 16008 may be further structured to command the atleast partial data redundancy in response to one of a fault condition ora failure condition 16012 related to, without limitation, at least oneof: one of the plurality of electric motors, an inverter operationallycoupled to one of the plurality of electric motors; a sensoroperationally coupled to one of the plurality of electric motors; and/ora local controller operationally coupled to one of the plurality ofelectric motors. The performance servicing circuit 16004 may be furtherstructured to determine the plurality of motor commands 16020 inresponse to the one of the fault condition or the failure condition16012, and further in response to data 16022 from the at least partialdata redundancy. The performance servicing circuit 16004 may be furtherstructured to suppress an operator notification 16018 of one of a faultcondition or a failure condition 16012 in response to a performancecapability 16016 of the plurality of electric motors being capable ofdelivering the application performance request value 16010. Theperformance servicing circuit 16004 may be further structured tocommunicate the suppressed operator notification 16018 to at least oneof a service tool 16030 or an external controller 16028, wherein theexternal controller 16028 and/or the service tool 16030 may be at leastintermittently communicatively coupled to the controller 15902. Theperformance servicing circuit 16004 may be further structured to adjustthe application performance request value 16010 in response to aperformance capability 16016 of the plurality of electric motors beingincapable of delivering the application performance request value 16010.

Referencing FIG. 161, an example procedure 16100 for controlling anelectric mobile application having a number of distributed motors isschematically depicted. In certain embodiments, the procedure 16100 maybe utilized with an electric mobile application having one or moredistributed driving elements (e.g., inverters) associated with one ormore of the distributed motors, and/or one or more distributedcontrollers for the inverters and/or motors. The distributed motors maybe configured to power various loads within the electric mobileapplication, and in certain embodiments, more than one motor may becapable to provide power to a particular load (e.g., motors associatedwith the wheels may be combined to provide overall motive power).Operations of the procedure 16100 may be performed by any controllers,circuits, and/or hardware arrangements as described throughout thepresent disclosure, and further may be performed in relation to any ofthe systems or hardware arrangements described throughout the presentdisclosure. The example procedure 16100 includes an operation 16102 tointerpret an application performance request value. Example andnon-limiting application performance request values include a motive orload power request, a motive or load torque request, and/or a motive orload speed request. The application performance request may be relatedto the entire application (e.g., a vehicle speed) and/or any portion ofthe application (e.g., a pump speed, a fan torque, etc.). The exampleprocedure 16100 includes an operation 16104 to determine a fault and/orfailure condition for one or more motors, inverters, and/or localcontrollers of the electric mobile application. The determination of afault and/or failure condition may further include determining acapability for the faulted or failed component (e.g., a de-rated motormay still be capable to provide some increment of power, and/or a motorhaving a failed inverter related to that motor may have some capabilityto receive power provided by another inverter in the system). In certainembodiments, for example where a motor is related to a local controllerfor the motor, and the local controller has failed, the motor maynevertheless be able to be controlled by another controller in thesystem and/or another local controller related to another motor in thesystem. In certain embodiments, the control of the motor by anothercontroller in the system may be de-rated—for example where the distantcontroller does not have one or more parameters available such atemperature value, a speed value, or another feedback value for themotor, and/or has a degraded version of any such parameter (e.g.,slower, lower resolution, and/or lower certainty), the distantcontroller may control the motor at a reduced power limit to protect themotor and/or the electric mobile application.

The example procedure 16100 further includes an operation 16106 todetermine motor commands in response to a motor capability description(e.g., motor ratings, including de-rates according to fault or failureconditions for related components, and/or due to the type of controlsuch as when a distant controller is operating the motor), theapplication performance request value, and the fault/failure conditionsof the motors. In certain embodiments, operation 16106 includesproviding sufficient performance across the available motors such thatthe application performance request value can be met. In certainembodiments, operation 16106 further includes providing commands to oneor more of the motors, local controllers, and/or related inverters inresponse to the determined motor commands.

In certain embodiments, the procedure 16100 further includes anoperation 16108 to command a data redundancy storage operation. Forexample, critical operating information such as motor or invertercalibrations, operating states, limitations, or the like, may be storedin more than one location. In certain embodiments, the operation 16108is responsive to fault or failure conditions in the electric mobileapplication, for example where a local controller, sensor, or othercomponent has a fault or failure condition, the operation 16108 mayinclude commanding data redundancy storage related to the component (orrelated components) having the fault or failure condition. In certainembodiments, the operation 16108 may include commanding data redundancystorage for components that do not have a fault or failure condition,and further enhancing the data redundancy storage in response to theoccurrence of a fault or failure condition. In certain embodiments, theoperation 16108 provides for data redundancy storage regardless of thefault or failure condition of components in the electric mobileapplication. Accordingly, operation 16108 provides for protection fromthe loss of data in response to the loss of a data storage component(e.g., parameters stored on a local controller), and provides forimproved control of components (e.g., inverters and/or motors) if anassociated local controller has a fault or failure and is not able tocontrol the related component and/or communicate out control parametersfor the local component after the fault or failure. In certainembodiments, data redundancy may include at least one data valueselected from the data values consisting of: a fault value, a systemstate, and a learning component value (e.g., control parameters relatedto a machine learning operation and/or real-time calibration values). Incertain embodiments, operation 16106 includes determining the motor,inverter, or local controller commands in response to the data in thedata redundancy storage. The operation 16108 to provide for dataredundancy storage includes distributing data in any manner within adata store available beyond the host data store, including at least adata store associated with any one or more of the following: anotherlocal controller, a master controller and/or a distributed (e.g.,virtual) controller, a powertrain controller, a vehicle controller,and/or an external controller (e.g., a manufacturer server, a fleetserver, a cloud-based server, a personal device such as an operator'ssmart phone, etc.).

The example procedure 16100 includes an operation 16110 to suppress anoperator notification (e.g., a warning or maintenance light, a vehicleresponse based notification, an app-based notification, or the like) ofa failure or fault (e.g., as determined in operation 16104) in responseto the available motor commands being capable to meet the applicationperformance request value. For example, if a motor derate occurs wherethe mission of the electric mobile application can still be met (e.g.,rated power is achievable, and/or a power request exceeding the currentcapability of the motors has not occurred or is not likely to occur),then operation 16110 may suppress the operator notification of the faultor failure indication that would normally occur. The example procedure16100 further includes an operation 16112 to communicate the suppressedoperator notifications (and/or the underlying fault or failurecondition(s)) to a service tool or external controller. For example, ifa motor derate occurs where the mission of the electric mobileapplication can still be met, the procedure 16100 may includesuppressing an operator notification, and notifying an externalcontroller (e.g., a fleet maintenance server, manufacturer server, orother external server) and/or a service tool (e.g., an OBD deviceconnecting to a communications port of the electric mobile application,a Wi-Fi based device in a service shop, etc.). Accordingly, inconvenientand/or expensive service events can be avoided, and/or servicing partiescan be notified such that the fault or failure can be addressed at aconvenient time and/or when the electric mobile application is alreadybeing serviced. In certain embodiments, the procedure 16100 includes anoperation (not shown) to receive parameters defining the types of faultsand/or failures that can be suppressed from operator notification,and/or performance limits and/or component types (relating to thefaults/failures) that can be suppressed from operator notification.Additionally or alternatively, the procedure 16100 includes an operation(not shown) to receive parameters defining the types of faults and/orfailures that are to be communicated to an external controller, and/orperformance limits and/or component types that are to be communicated tothe external controller. Additionally or alternatively, the procedure16100 includes an operation (not shown) defining operator notificationtypes that should be suppressed (e.g., where one type of operatornotification is suppressed and another is executed), and/or the timingor locations of external controller notifications.

The methods and systems described herein may be deployed in part or inwhole through a machine having a computer, computing device, processor,circuit, and/or server that executes computer readable instructions,program codes, instructions, and/or includes hardware configured tofunctionally execute one or more operations of the methods and systemsdisclosed herein. The terms computer, computing device, processor,circuit, and/or server, as utilized herein, should be understoodbroadly.

Any one or more of the terms computer, computing device, processor,circuit, and/or server include a computer of any type, capable to accessinstructions stored in communication thereto such as upon anon-transient computer readable medium, whereupon the computer performsoperations of systems or methods described herein upon executing theinstructions. In certain embodiments, such instructions themselvescomprise a computer, computing device, processor, circuit, and/orserver. Additionally or alternatively, a computer, computing device,processor, circuit, and/or server may be a separate hardware device, oneor more computing resources distributed across hardware devices, and/ormay include such aspects as logical circuits, embedded circuits,sensors, actuators, input and/or output devices, network and/orcommunication resources, memory resources of any type, processingresources of any type, and/or hardware devices configured to beresponsive to determined conditions to functionally execute one or moreoperations of systems and methods herein.

Network and/or communication resources include, without limitation,local area network, wide area network, wireless, internet, or any otherknown communication resources and protocols. Example and non-limitinghardware, computers, computing devices, processors, circuits, and/orservers include, without limitation, a general purpose computer, aserver, an embedded computer, a mobile device, a virtual machine, and/oran emulated version of one or more of these. Example and non-limitinghardware, computers, computing devices, processors, circuits, and/orservers may be physical, logical, or virtual. A computer, computingdevice, processor, circuit, and/or server may be: a distributed resourceincluded as an aspect of several devices; and/or included as aninteroperable set of resources to perform described functions of thecomputer, computing device, processor, circuit, and/or server, such thatthe distributed resources function together to perform the operations ofthe computer, computing device, processor, circuit, and/or server. Incertain embodiments, each computer, computing device, processor,circuit, and/or server may be on separate hardware, and/or one or morehardware devices may include aspects of more than one computer,computing device, processor, circuit, and/or server, for example asseparately executable instructions stored on the hardware device, and/oras logically partitioned aspects of a set of executable instructions,with some aspects of the hardware device comprising a part of a firstcomputer, computing device, processor, circuit, and/or server, and someaspects of the hardware device comprising a part of a second computer,computing device, processor, circuit, and/or server.

A computer, computing device, processor, circuit, and/or server may bepart of a server, client, network infrastructure, mobile computingplatform, stationary computing platform, or other computing platform. Aprocessor may be any kind of computational or processing device capableof executing program instructions, codes, binary instructions and thelike. The processor may be or include a signal processor, digitalprocessor, embedded processor, microprocessor or any variant such as aco-processor (math co-processor, graphic co-processor, communicationco-processor and the like) and the like that may directly or indirectlyfacilitate execution of program code or program instructions storedthereon. In addition, the processor may enable execution of multipleprograms, threads, and codes. The threads may be executed simultaneouslyto enhance the performance of the processor and to facilitatesimultaneous operations of the application. By way of implementation,methods, program codes, program instructions and the like describedherein may be implemented in one or more threads. The thread may spawnother threads that may have assigned priorities associated with them;the processor may execute these threads based on priority or any otherorder based on instructions provided in the program code. The processormay include memory that stores methods, codes, instructions and programsas described herein and elsewhere. The processor may access a storagemedium through an interface that may store methods, codes, andinstructions as described herein and elsewhere. The storage mediumassociated with the processor for storing methods, programs, codes,program instructions or other type of instructions capable of beingexecuted by the computing or processing device may include but may notbe limited to one or more of a CD-ROM, DVD, memory, hard disk, flashdrive, RAM, ROM, cache and the like.

A processor may include one or more cores that may enhance speed andperformance of a multiprocessor. In embodiments, the process may be adual core processor, quad core processors, other chip-levelmultiprocessor and the like that combine two or more independent cores(called a die).

The methods and systems described herein may be deployed in part or inwhole through a machine that executes computer readable instructions ona server, client, firewall, gateway, hub, router, or other such computerand/or networking hardware. The computer readable instructions may beassociated with a server that may include a file server, print server,domain server, internet server, intranet server and other variants suchas secondary server, host server, distributed server and the like. Theserver may include one or more of memories, processors, computerreadable transitory and/or non-transitory media, storage media, ports(physical and virtual), communication devices, and interfaces capable ofaccessing other servers, clients, machines, and devices through a wiredor a wireless medium, and the like. The methods, programs, or codes asdescribed herein and elsewhere may be executed by the server. Inaddition, other devices required for execution of methods as describedin this application may be considered as a part of the infrastructureassociated with the server.

The server may provide an interface to other devices including, withoutlimitation, clients, other servers, printers, database servers, printservers, file servers, communication servers, distributed servers, andthe like. Additionally, this coupling and/or connection may facilitateremote execution of instructions across the network. The networking ofsome or all of these devices may facilitate parallel processing ofprogram code, instructions, and/or programs at one or more locationswithout deviating from the scope of the disclosure. In addition, all thedevices attached to the server through an interface may include at leastone storage medium capable of storing methods, program code,instructions, and/or programs. A central repository may provide programinstructions to be executed on different devices. In thisimplementation, the remote repository may act as a storage medium formethods, program code, instructions, and/or programs.

The methods, program code, instructions, and/or programs may beassociated with a client that may include a file client, print client,domain client, internet client, intranet client and other variants suchas secondary client, host client, distributed client and the like. Theclient may include one or more of memories, processors, computerreadable transitory and/or non-transitory media, storage media, ports(physical and virtual), communication devices, and interfaces capable ofaccessing other clients, servers, machines, and devices through a wiredor a wireless medium, and the like. The methods, program code,instructions, and/or programs as described herein and elsewhere may beexecuted by the client. In addition, other devices utilized forexecution of methods as described in this application may be consideredas a part of the infrastructure associated with the client.

The client may provide an interface to other devices including, withoutlimitation, servers, other clients, printers, database servers, printservers, file servers, communication servers, distributed servers, andthe like. Additionally, this coupling and/or connection may facilitateremote execution of methods, program code, instructions, and/or programsacross the network. The networking of some or all of these devices mayfacilitate parallel processing of methods, program code, instructions,and/or programs at one or more locations without deviating from thescope of the disclosure. In addition, all the devices attached to theclient through an interface may include at least one storage mediumcapable of storing methods, program code, instructions, and/or programs.A central repository may provide program instructions to be executed ondifferent devices. In this implementation, the remote repository may actas a storage medium for methods, program code, instructions, and/orprograms.

The methods and systems described herein may be deployed in part or inwhole through network infrastructures. The network infrastructure mayinclude elements such as computing devices, servers, routers, hubs,firewalls, clients, personal computers, communication devices, routingdevices and other active and passive devices, modules, and/or componentsas known in the art. The computing and/or non-computing device(s)associated with the network infrastructure may include, apart from othercomponents, a storage medium such as flash memory, buffer, stack, RAM,ROM and the like. The methods, program code, instructions, and/orprograms described herein and elsewhere may be executed by one or moreof the network infrastructural elements.

The methods, program code, instructions, and/or programs describedherein and elsewhere may be implemented on a cellular network havingmultiple cells. The cellular network may either be frequency divisionmultiple access (FDMA) network or code division multiple access (CDMA)network. The cellular network may include mobile devices, cell sites,base stations, repeaters, antennas, towers, and the like.

The methods, program code, instructions, and/or programs describedherein and elsewhere may be implemented on or through mobile devices.The mobile devices may include navigation devices, cell phones, mobilephones, mobile personal digital assistants, laptops, palmtops, netbooks,pagers, electronic books readers, music players, and the like. Thesemobile devices may include, apart from other components, a storagemedium such as a flash memory, buffer, RAM, ROM and one or morecomputing devices. The computing devices associated with mobile devicesmay be enabled to execute methods, program code, instructions, and/orprograms stored thereon. Alternatively, the mobile devices may beconfigured to execute instructions in collaboration with other devices.The mobile devices may communicate with base stations interfaced withservers and configured to execute methods, program code, instructions,and/or programs. The mobile devices may communicate on a peer to peernetwork, mesh network, or other communications network. The methods,program code, instructions, and/or programs may be stored on the storagemedium associated with the server and executed by a computing deviceembedded within the server. The base station may include a computingdevice and a storage medium. The storage device may store methods,program code, instructions, and/or programs executed by the computingdevices associated with the base station.

The methods, program code, instructions, and/or programs may be storedand/or accessed on machine readable transitory and/or non-transitorymedia that may include: computer components, devices, and recordingmedia that retain digital data used for computing for some interval oftime; semiconductor storage known as random access memory (RAM); massstorage typically for more permanent storage, such as optical discs,forms of magnetic storage like hard disks, tapes, drums, cards and othertypes; processor registers, cache memory, volatile memory, non-volatilememory; optical storage such as CD, DVD; removable media such as flashmemory (e.g., USB sticks or keys), floppy disks, magnetic tape, papertape, punch cards, standalone RAM disks, Zip drives, removable massstorage, off-line, and the like; other computer memory such as dynamicmemory, static memory, read/write storage, mutable storage, read only,random access, sequential access, location addressable, fileaddressable, content addressable, network attached storage, storage areanetwork, bar codes, magnetic ink, and the like.

Certain operations described herein include interpreting, receiving,and/or determining one or more values, parameters, inputs, data, orother information. Operations including interpreting, receiving, and/ordetermining any value parameter, input, data, and/or other informationinclude, without limitation: receiving data via a user input; receivingdata over a network of any type; reading a data value from a memorylocation in communication with the receiving device; utilizing a defaultvalue as a received data value; estimating, calculating, or deriving adata value based on other information available to the receiving device;and/or updating any of these in response to a later received data value.In certain embodiments, a data value may be received by a firstoperation, and later updated by a second operation, as part of thereceiving a data value. For example, when communications are down,intermittent, or interrupted, a first operation to interpret, receive,and/or determine a data value may be performed, and when communicationsare restored an updated operation to interpret, receive, and/ordetermine the data value may be performed.

Certain logical groupings of operations herein, for example methods orprocedures of the current disclosure, are provided to illustrate aspectsof the present disclosure. Operations described herein are schematicallydescribed and/or depicted, and operations may be combined, divided,re-ordered, added, or removed in a manner consistent with the disclosureherein. It is understood that the context of an operational descriptionmay require an ordering for one or more operations, and/or an order forone or more operations may be explicitly disclosed, but the order ofoperations should be understood broadly, where any equivalent groupingof operations to provide an equivalent outcome of operations isspecifically contemplated herein. For example, if a value is used in oneoperational step, the determining of the value may be required beforethat operational step in certain contexts (e.g. where the time delay ofdata for an operation to achieve a certain effect is important), but maynot be required before that operation step in other contexts (e.g. whereusage of the value from a previous execution cycle of the operationswould be sufficient for those purposes). Accordingly, in certainembodiments an order of operations and grouping of operations asdescribed is explicitly contemplated herein, and in certain embodimentsre-ordering, subdivision, and/or different grouping of operations isexplicitly contemplated herein.

The methods and systems described herein may transform physical and/oror intangible items from one state to another. The methods and systemsdescribed herein may also transform data representing physical and/orintangible items from one state to another.

The elements described and depicted herein, including in flow charts,block diagrams, and/or operational descriptions, depict and/or describespecific example arrangements of elements for purposes of illustration.However, the depicted and/or described elements, the functions thereof,and/or arrangements of these, may be implemented on machines, such asthrough computer executable transitory and/or non-transitory mediahaving a processor capable of executing program instructions storedthereon, and/or as logical circuits or hardware arrangements. Examplearrangements of programming instructions include at least: monolithicstructure of instructions; standalone modules of instructions forelements or portions thereof; and/or as modules of instructions thatemploy external routines, code, services, and so forth; and/or anycombination of these, and all such implementations are contemplated tobe within the scope of embodiments of the present disclosure Examples ofsuch machines include, without limitation, personal digital assistants,laptops, personal computers, mobile phones, other handheld computingdevices, medical equipment, wired or wireless communication devices,transducers, chips, calculators, satellites, tablet PCs, electronicbooks, gadgets, electronic devices, devices having artificialintelligence, computing devices, networking equipment, servers, routersand the like. Furthermore, the elements described and/or depictedherein, and/or any other logical components, may be implemented on amachine capable of executing program instructions. Thus, while theforegoing flow charts, block diagrams, and/or operational descriptionsset forth functional aspects of the disclosed systems, any arrangementof program instructions implementing these functional aspects arecontemplated herein. Similarly, it will be appreciated that the varioussteps identified and described above may be varied, and that the orderof steps may be adapted to particular applications of the techniquesdisclosed herein. Additionally, any steps or operations may be dividedand/or combined in any manner providing similar functionality to thedescribed operations. All such variations and modifications arecontemplated in the present disclosure. The methods and/or processesdescribed above, and steps thereof, may be implemented in hardware,program code, instructions, and/or programs or any combination ofhardware and methods, program code, instructions, and/or programssuitable for a particular application. Example hardware includes adedicated computing device or specific computing device, a particularaspect or component of a specific computing device, and/or anarrangement of hardware components and/or logical circuits to performone or more of the operations of a method and/or system. The processesmay be implemented in one or more microprocessors, microcontrollers,embedded microcontrollers, programmable digital signal processors orother programmable device, along with internal and/or external memory.The processes may also, or instead, be embodied in an applicationspecific integrated circuit, a programmable gate array, programmablearray logic, or any other device or combination of devices that may beconfigured to process electronic signals. It will further be appreciatedthat one or more of the processes may be realized as a computerexecutable code capable of being executed on a machine readable medium.

The computer executable code may be created using a structuredprogramming language such as C, an object oriented programming languagesuch as C++, or any other high-level or low-level programming language(including assembly languages, hardware description languages, anddatabase programming languages and technologies) that may be stored,compiled or interpreted to run on one of the above devices, as well asheterogeneous combinations of processors, processor architectures, orcombinations of different hardware and computer readable instructions,or any other machine capable of executing program instructions.

Thus, in one aspect, each method described above and combinationsthereof may be embodied in computer executable code that, when executingon one or more computing devices, performs the steps thereof. In anotheraspect, the methods may be embodied in systems that perform the stepsthereof, and may be distributed across devices in a number of ways, orall of the functionality may be integrated into a dedicated, standalonedevice or other hardware. In another aspect, the means for performingthe steps associated with the processes described above may include anyof the hardware and/or computer readable instructions described above.All such permutations and combinations are contemplated in embodimentsof the present disclosure.

While the methods and systems described herein have been disclosed inconnection with certain preferred embodiments shown and described indetail, various modifications and improvements thereon may becomereadily apparent to those skilled in the art. Accordingly, the spiritand scope of the methods and systems described herein is not to belimited by the foregoing examples, but is to be understood in thebroadest sense allowable by law.

All documents referenced herein are hereby incorporated by reference.

What is claimed is:
 1. A system, comprising: a vehicle having a motive electrical power path; a power distribution unit having a current protection circuit disposed in the motive electrical power path, the current protection circuit comprising a fuse; a controller, comprising: a fuse status circuit structured to determine a fuse event value; a fuse management circuit structured to provide a fuse event response based on the fuse event value; and a fuse life description circuit structured to determine a fuse life remaining value, wherein the fuse event value comprises a representation that the fuse life remaining value is below a threshold value, and wherein the fuse management circuit is further structured to provide the fuse event response further based on the fuse life remaining value.
 2. The system of claim 1, further comprising, a current source circuit, wherein the power distribution unit further comprises a plurality of fuses, and wherein the current source circuit is further structured to inject a current across each of the plurality of fuses in a selected sequence.
 3. The system of claim 2, wherein the current source circuit is further structured to inject the current across a first one of the plurality of fuses at a first shutdown event of the vehicle, and to inject the current across a second one of the plurality of fuses at a second shutdown event of the vehicle.
 4. The system of claim 1, further comprising a current source circuit structured to determine a load power throughput of the motive electrical power path is low in response to a shutdown state.
 5. The system of claim 1, further comprising, a fuse thermal model circuit structured to determine a fuse temperature value of the fuse in response to at least one of an injected voltage amount and a thermal fuse impedance value.
 6. The system of claim 1, wherein the power distribution unit further comprises a plurality of breaker/relay devices disposed therein, and a current source circuit electrically coupled to the plurality of breaker/relay devices, and structured to sequentially inject a current across each fixed contact of the plurality of breaker/relay devices; and a voltage determination circuit electrically coupled to each of the plurality of breaker/relay devices, and further structured to determine at least one of an injected voltage amount and a contactor impedance value for each of the plurality of breaker/relay devices.
 7. The system of claim 6, wherein the voltage determination circuit further comprises a bandpass filter having a bandwidth selected to bound a frequency of an injected current.
 8. The system of claim 6, wherein the current source circuit is further structured to sequentially inject the current across each of the plurality of breaker/relay devices in a selected order of the plurality of breaker/relay devices.
 9. The system of claim 8, wherein the current source circuit is further structured to adjust the selected order in response to one of a planned duty cycle and an observed duty cycle of a vehicle.
 10. The system of claim 6, wherein the current source circuit is further structured to adjust a selected order in response to at least one of: a rate of change of a temperature of a fixed contact of the plurality of breaker/relay devices; an importance value of each of the plurality of breaker/relay devices; a criticality of each of the plurality of breaker/relay devices; a power throughput of each of plurality of breaker/relay devices; and one of a fault condition or a contactor health condition of each of the plurality of breaker/relay devices.
 11. The system of claim 1, further comprising, a load current circuit structured to determine a load current through a fuse in response to a thermal fuse impedance value.
 12. A controller, comprising: a fuse status circuit structured to determine a fuse event value; a fuse management circuit structured to provide a fuse event response based on the fuse event value; and a fuse life description circuit structured to determine a fuse life remaining value, wherein the fuse event value comprises a representation that the fuse life remaining value is below a threshold value, and wherein the fuse management circuit is further structured to provide the fuse event response further based on the fuse life remaining value.
 13. The controller of claim 12, further comprising, a fuse thermal model circuit structured to determine a fuse temperature value of a fuse in response to at least one of an injected voltage amount and a thermal fuse impedance value.
 14. The controller of claim 12, further comprising, a load current circuit structured to determine a load current through a fuse in response to a thermal fuse impedance value.
 15. The controller of claim 12, further comprising, a current source circuit structured to determine a load power throughput of a motive electrical power path is low in response to a shutdown state.
 16. The controller of claim 12, further comprising, a voltage determination circuit comprising a bandpass filter having a bandwidth selected to bound a frequency of an injected current.
 17. A method, comprising: determining a fuse event value; providing a fuse event response based on the fuse event value; determining a fuse life remaining value, wherein the fuse event value comprises a representation that the fuse life remaining value is below a threshold value; and providing the fuse event response further based on the fuse life remaining value.
 18. The method of claim 17, further comprising, determining a fuse temperature value of a fuse in response to at least one of an injected voltage amount and a thermal fuse impedance value.
 19. The method of claim 17, further comprising, determining a load current through a fuse in response to a thermal fuse impedance value.
 20. The method of claim 17, further comprising, bounding a frequency of an injected current with a bandpass filter. 